A C O M P L E T E F A M I LY O F L E A KD E T E C T I O N E Q U I P M E N T F O RT H E A E R O N A U T I C A L I N D U S T R Y

Varian offers the HeliTest WING, a completefamily of modular instrumentation,specifically designed and developed byVarian to allow easy service andmaintenance activity for all leak detectionrequirements on an aircraft.The HeliTest WING is the ideal solution inaircraft ground support centers andmanufacturing facilities, for use both in civiland military aircraft.The helium technique used for leak detectionpurpose has been approved by the majoraircraft manufacturers and has become aworld-wide standard.The HeliTest WING family is packaged toallow ease of transportation when requiredto perform tests on grounded aircraftlocated at remotesites. Themodules thatcompose theHeliTest WINGfamily are:

1 - HeliTest WING Detection Unit

The HeliTest WING Detection Unit is the coreof this equipment.Its operation is based on a new technologycalled SIPD (Selective Ion Pump Detector),which provides high sensitivity andselectivity, and allows precise leak locationwith no uncertainty. This technology makesuse of a special silica membrane, which, ifheated, becomes permeable to helium butnot to other gases, because of the small sizeof the helium molecule. An ion pump willdetect and display a signal proportional tothe quantity of helium that has permeated

through the membrane, and this signal willbe displayed showing the helium leak rate.This system of operation is highly sensitive,due to the very low pressure in the ionpump (10-9 mbar), and very reliable, due tothe absence of moving parts.A calibrated leak, useful to periodically checkproper calibration of this instrument, isincluded.

2 - HeliTest WING Visual Probe Unit

The Visual Probe Unit consists of the VisualProbe and its Control Unit.The Probe is needed to pinpoint the actualleak location even in hazardous conditions.The operator will pass it slowly above theareas suspected to be leaking, until a leaksignal is indicated. The leak signal appears

directly on the bar graph, installedon the Probe, which makesleak pin pointing veryprecise and convenient.The bar graph allows notonly to identify the leak

location, but also itssize with considerable

approximation. The Visual Probe is

“Intrinsically Safe”,certified according to

CENELEC safety standards. Therefore itcan be used inside the aircraft tank even inpresence of some amount of fuel vapors.The Visual Probe is connected to the ControlUnit with a 10 meter (32’) cable. The ControlUnit itself must be located outside of the fueltank, and connected to the HeliTest WINGDetection Unit.

3 - HeliTest WING Fuel Tooling Unit

This unit comprises the items necessary forproper helium pressurization of the areas tobe tested, including all necessary fittings,

valves and injection chambers required toperform the leak checking activity. A Venturipump, whose purpose is to isolate the areaswhere helium must be injected from areaswhere helium must be absent, is included forprecise leak location. This pump is also helpfulin order to remove excessive amount of helium,which can be present after long duration oftests. Compressed air source is required.

4 - HeliTest WING Oxygen Lines Test Unit

This kit includes the equipment needed toperform leak tests on an aircraft oxygenlines. It contains a pressure decay controlsystem with temperature variationmonitoring and helium pressurization circuitfor helium injection at the required testpressure. All components of this unit arefully degreased and a pollution qualitycontrol certificate is included.

5 - HeliTest WING Mobile Trunk

This is a rugged roll-mounted container withmetal reinforced corners, suitable forfrequent air or ground transfers. The trunkhas form fitted internal compartments andallows adequate space to contain thenecessary HeliTest WING modules fortransportation.

. . . H e l i Te s t W I N G , t h e s o l u t i o n

High quality standards, backed by tightcontrols, are today mandatory in theaeronautical industry.Particularly important are a number of leakdetection checks that must be performedon various parts of an aircraft, during eitherscheduled maintenance overhauls orunforeseen emergencies in airportsanywhere in the world.Looking for leaks in a fuel tank is a delicatejob which requires complete knowledge ofthe aircraft structure, ability in locating

leaks on the outside of the tank, as well ason its inside, in order to allow to proceed tothe necessary repair on the leaking point ofthe “PR” sealing.Very often the need is present to performleak checks when the aircraft tank stillcontains fuel vapors. The need to useequipment designed for this application,including the safety aspects, is mandatory.The HeliTest WING offers certified“intrinsically safe” instrumentation, as wellas the required tools necessary for the

operators to perform this critical leak testactivity.In addition, the HeliTest WING can be usedto check the quality of the repair, savingtime and costs.The oxygen distribution network, both inthe cockpit and in the passengers area,requires careful checks to make sure thatthe oxygen distribution lines are notaffected by leaks in any point of the pipingand fitting assembly. The same care mustbe applied on pilot masks in a militaryaircraft.

Many other leak detection jobs are normallyrequired in an aircraft.We can mention the following:

• Anemometric circuit• Pneumatic landing system• Wind screens• Engine fire extinguisher systems• Bleed circuits• Main and auxiliary tanks on military

aircraft.

As of today, several leak detection methodsare in use, but they are time consuming, donot have the required sensitivity and do notallow precise leak location. None of themhas been specifically designed for aircrafttesting.

T h e n e e d . . .

WHY USE HELIUM AS A TRACER GAS

The leak detection technique is based onthe use of helium as a tracer gas: helium isvery widely used as a tracer gas for somevery important reasons:

• InertHelium is a non-toxic gas which doesnot react chemically with any otherelement, making it safe for leak detectionapplications.

• Highly penetratingDue to its small molecule, helium easilypasses through the smallest leaks.

• Low natural background in airThe helium concentration in air is only 5ppm, which allows detection of even thesmallest leaks with little backgroundinterference.

Samho Syscom Ent. / www.vacuum.co.kr Varian, Inc. Vacuum Technologies Samho Syscom Ent. / www.vacuum.co.kr Varian, Inc. Vacuum Technologies

LEAK CHECKING AIRCRAFT FUELTANKS IN PRODUCTION

In aircraft manufacturing process, the needis to perform a total leak check in order tohave quality assurance final inspection ofthe manufacturing process. The approachconsists in pressurizing the tank with a 5 %helium / air mixture at a pressure of about300 mbar and to inspect the outside forleaks generating a helium concentrationhigher than 100 ppm. This test can also beperformed after a major overhaul, beforerefueling the aircraft.

LEAK CHECKING AIRCRAFT FUELTANKS IN SERVICE

In aircraft maintenance process, the need isto precisely locate the internal leak sources,after performing a clear mapping fromoutside. Varian has performed extensivetests, and has devised a very efficient testmethod.A helium injection chamber, built accordingto the aircraft manufacturer requirements,is used on the outside of the tank undertest. The chamber can be made using aplastic bag, or a rubber mouth piece. Aslight helium overpressure is kept insidethe chamber during the inspection of theinside of the tank with the HeliTest WING.The Venturi pump is used to pump awayany residual helium which might be presentin the air close to the area under test. Soonly the test area is pressurized withhelium, and changing the size of theinjection chambers will proportionallychange the surface of the area underpressure. This way even a small leak can beprecisely identified.The operator connects the HeliTest WINGDetection Unit to the Visual Probe ControlUnit and inserts the Visual Probe inside thetank. The Visual Probe is certified“Intrinsically Safe” and can be inserted inthe tank even in the presence of fuelvapors. The Probe is then slowly passedabove the test area and any signal indicatesthe presence of a leak.Once all leaks have been found andrepaired, it is possible to check the qualityof repairs without any refueling, minimizingthe down time. Varian has repeatedlyproven that this technique allows to save

more than 40 % working time on fuel tankleak repairs, with excellent results.Several aircraft manufacturers have alreadyissued repair instructions validating the useof helium technique with HeliTest WING,for accurate detection of fuel leak sources.

LEAK CHECKING AIRCRAFT OXYGENDISTRIBUTION LINES

Varian offers the Oxygen Lines Test Unit,which provides the equipment necessary topressurize the oxygen lines with helium.After a global pressure decay leak check, itis possible to use the HeliTest WINGDetection Unit and pass the Visual Probeover the critical areas in order to identifyany leaks.

OTHER LEAK DETECTIONAPPLICATIONS

Other pneumatic circuitry in an aircraft mayrequire leak checking. The HeliTest WINGhas been used in leak tests of the“Anemometer Circuit” and the “FireExtinguisher Line”.The former application is particularlyimportant due to the intrinsic difficulty toperform sensitive pressure decay leakchecks, as this type of circuit does notallow more than 20 mbar (0.3 psi)overpressure.High sensitivity of HeliTest WING allows to

perform this test in short time and with a1000 times better sensitivity thanalternative techniques.

OPERATIONAL TRAINING

Varian offers professional training, toenable operators become familiar with theinstrument and with the application. Atypical training session for HeliTest WINGlasts three days. About half of the time isspent on theoretical training, and theremainder on practical “hands on”sessions.

H o w t o u s e H e l i Te s t W I N G

He

FUELTOOLING

UNITCONTROL

UNITDETECTION

UNIT12 V

BATTERY

PROBE

RIB

SKIN

FUELTANK

VISUALLEAK INDICATOR

H e l i T e s t W I N G O p e r a t i o n

Samho Syscom Ent. / www.vacuum.co.kr Varian, Inc. Vacuum Technologies

H e l i Te s t W I N G S p e c i f i c a t i o n s H e l i Te s t W I N G O r d e r i n g I n f o r m a t i o n

Description Part NumberHeliTest WING Detection Unit 969-4000

Includes:- Modified HeliTest basic unit- Two batteries- One battery charger, AC/DC converter- Carrying straps- Probe pin head assembly- Calibrated leak (helium concentration range 20-200 ppm)- Travelling case

HeliTest WING Visual Probe Unit 969-4100Includes:- Visual Probe Control Unit with flow regulator, flame stopper and

Zener barrier protection- Intrinsically Safe Visual Probe, with bar graph display and remote

control fixed zero / auto zero function- 10 meter (32’) connection line to the Visual Probe

HeliTest WING Fuel Tooling Unit 969-4300Includes:- Helium supply assembly, gas distribution network from an inlet pressure

of 5 bar (70 PSI) to the operating pressure, including pipes and connectors- Compression air and venting supply assembly, including necessary

connectors, Venturi pump and on/off valve- Set of rubber pieces for quick injection- Travelling case

HeliTest WING Oxygen Lines Test Unit 969-4200HeliTest WING Mobile Trunk 969-4449HeliTest WING Operational Training TR01000

A three-day professional theoretical and practical training course foroptimum use of HeliTest WING in aircraft applications

SPARE PARTSDescription Part NumberAdditional HeliTest WING Basic Detection Unit 969-4001

AUSTRALIA – Varian Australia Pty Ltd. – 6/81 Frenchs Forest Road – Frenchs Forest NSW 2086 – Australia – Telephone: (61) 299758805 – Fax: (61) 294522600BENELUX – Varian Vacuum Technologies – Rijksstraatweg 269 H, – 3956 CP Leersum – The Netherlands – Telephone: (31) 343469910 – Fax: (31) 343469961

CANADA – Varian Canada Inc. – 6705 Millcreek Drive, Unit 5 – Mississauga, Ontario L5N 5R9 – Canada – Telephone: (905) 8198188 – Fax: (905) 8198348 – Toll free: 1 800 6632727CHINA – Varian Technologies Asia, Ltd. – Rm. 2611 Concordia Plaza – 1 Science Museum Rd – Tsimshatsui East, Kowloon – Hong Kong – Telephone: (852) 26206173 – Fax: (852) 26206338

FRANCE & WALLONIE – Varian s.a. – 7, Avenue des Tropiques – Z.A. de Courtaboeuf B.P. 12 – F91941 Les Ulis Cedex - France – Telephone: (33) 1 69863884 – Fax: (33) 1 69282308GERMANY, AUSTRIA – Varian Deutschland GmbH – Vacuum Technologies – Alsfelder Strasse 6 – Postfach 11 14 35 – 64289 Darmstadt - Germany – Telephone: (49) 6151703353 – Fax: (49) 6151703302

INDIA – Varian India Pvt. Ltd. – 101 Competent House – 7, Nangal Raya Business Centre – New Delhi 110 046 - India – Telephone: (91) 11 5548444 – Fax: (91) 11 5548445ITALY – Varian Vacuum Technologies – Varian S.p.A. - VT Sales Office – Via Varian 54 – 10040 Leinì (Torino) – Italy – Telephone: (39) 011 9979111 – Fax: (39) 011 9979316

JAPAN – Varian Technologies Japan – Sumitomo Shibaura Bldg. – 4-16-36 Shibaura Minato ku – Tokyo 108 – Japan – Telephone: (81) 352321211 – Fax: (81) 352321263KOREA – Varian Technologies Korea, Ltd. – Head Office – Shinsa 2nd Bldg. 2F, 966-5 – Daechi-Dong, Kangnam-Seoul – Korea 135-280 – Telephone: (82) 234522452 – Fax: (82) 234522451

SPAIN – Varian Iberica S.L. – Avenida Pedro Diez, 25, 3rd Floor – E-28019 Madrid – Spain – Telephone: (34) 91 4727612 – Fax: (34) 1 4725001TAIWAN – Varian Technologies Asia, Ltd. – Taiwan Branch – 18F-13 No. 79, Sec. 1, Hsin Tai Wu Rd. – Hsi Chih, Taipei Hsien, Taiwan – Telephone: (886) 2 26989555 – Fax: (886) 2 26989678

U.K. & IRELAND – Varian Ltd. – 28 Manor Road – Walton on Thames – Surrey KT12 2QF – U.K. – Telephone: (44) 1932 898000 – Fax: (44) 1932 228769USA, SOUTH & CENTRAL AMERICA – Varian Vacuum Technologies – 121 Hartwell Avenue – Lexington, MA 02421 – USA – Telephone: (781) 8617200 – Fax: (781) 8605437 – Toll free: 1 800 8827426

OTHER COUNTRIES – Varian Vacuum Technologies – Varian S.p.A. - VT Sales Office – Via Varian 54 – 10040 Leinì (Torino) – Italy – Telephone: (39) 011 9979111 – Fax: (39) 011 9979316

V a r i a n O f f i c e s

VAC-

T029

-E (P

rinte

d in

Ital

y) 0

4/20

00

HeliTest WING Detection UnitLowest detectable helium concentration: 2 ppm (parts per million)Lowest detectable leak rate: 5 x 10-6 mbar l/sResponse time: 5 secondsWarm up time including self-check up: 3 minutes (approx.)Power requirement: 12 Vdc, 1.2 ABattery unit: Sealed detachable

rechargeable batteryOperating conditions:

Temperature: -20° C to +40° CRelative humidity: 90% maximum

Size: 200 x 170 x 90 mm(7.9” x 6.7” x 3.5”)

Weight:HeliTest without battery: 2.0 kg (4.5 lbs)Battery: 2.2 kg (5.0 lbs)

HeliTest WING Visual Probe UnitVisual Probe Safety Specification: EEx ia II A T4Visual Probe Control Unit size: 140 x 170 x 210 mm

(5.5” x 6.7” x 8.3”)Visual Probe Control Unit weight: 5.5 kg (12.1 lbs)Connecting cable length: 10 m (32’)

HeliTest WING Fuel Tooling UnitSize: 570 x 430 x 240 mm

(23” x 17” x 10”)Weight: 12.5 kg (27.5 lbs)

HeliTest WING Mobile TrunkSize: 630 x 610 x 1105 mm

(25” x 24” x 44”)Weight: 34.5 kg (76 lbs)

All specifications are subject to change without notice - Copyright by Varian SpA

Samho Syscom Ent. / www.vacuum.co.kr