Silent Threat: Carbon Monoxide Poisoning Risks for Pilots
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Cold weather can mean better airplane performance and some beautiful winter sunrises, but it can also mean potential danger from the airplane’s exhaust manifold heating system. Since 2010, there have been 12 fatal aircraft accidents where CO impairment was the primary root cause. In the small, unpressurized cabins of general aviation aircraft, any carbon monoxide (CO) that enters the cabin can quickly reach a significant and dangerous concentration. Here’s what pilots need to know about carbon monoxide: where it comes from, how to prevent it from entering the cockpit, and what tools are available for detecting it.
Carbon Monoxide Dangers
Most light airplane heaters use a shroud around the exhaust to warm ambient air, which is a simple and effective way to keep pilots and passengers warm. Unfortunately, a leak in the exhaust system means carbon monoxide, a colorless, odorless, tasteless—and potentially deadly—gas, can enter the cabin.
This is dangerous because CO essentially tricks your blood into bonding with it instead of oxygen, starving your body of what it needs. With enough exposure, this can lead to symptoms of hypoxia (anemic hypoxia, specifically). At low levels, that might mean just a headache, but over a long enough period of time or with high enough CO concentrations, that might mean impaired decision-making or even incapacitation. Worst of all, your brain won’t notice anything is wrong—if you don’t have some way to monitor CO in the airplane, you might never know it’s there.
Sadly, accidents can and do happen. In fact, I narrowly avoided one myself a few years ago. A crack in the exhaust sytem of the helicopter I was flying meant unfiltered exhaust gasses were pouring into the cockpit every time I pulled the cabin heat knob. It was only because I had a good CO detector that I stayed out of the NTSB reports.
Heaters in most light airplanes use air that is warmed by passing through a shroud around the hot engine exhaust pipes—the most likely source of carbon monoxide.
Carbon Monoxide Prevention
One way to avoid this scenario is to perform a good preflight inspection every time you fly, paying particular attention to the condition of the exhaust system. Look for any cracks, holes, or hot spots, which might indicate a leak. Since much of this is hidden with the engine cowl on, have your mechanic do a thorough inspection of all exhaust parts at every oil change and annual, too.
The easiest thing to do is use a carbon monoxide detector on every flight. If you buy a quality device and make it part of your regular checklist, you’re much more likely to detect a leak before it becomes a major problem. In fact, the NTSB now strongly suggests that all airplanes have some type of CO detector on board. All CO detectors measure concentration in parts per million (ppm), and alert pilots with some combination of lights, audio alarms, and even vibration.
So how much is too much? The US Occupational Safety and Health Administration (OSHA) uses 35 ppm as its lower limit, although it’s important to note that this is based on a time weighted average (TWA), taken over 8 hours. OSHA uses 200 ppm as a 5-minute sample ceiling, and 1500 ppm as an instantaneous limit.
In our experience, pilots should err on the side of caution. Certainly a concentration of 200 ppm should get your attention right away: turn off the heat, open the fresh air vents, and consider landing. It’s highly likely you have an exhaust leak. But pilots can also be impacted by much lower levels. Even 35 ppm, which could be caused by poor airflow or even the landing gear being down, can cause confusion, fatigue, and poor decision making if it persists for an hour. For that reason, we like units that alert at 35 or 50 ppm.
Flying with a CO detector is only helpful if you know how to use it. Make sure the batteries are fresh and the sensor is replaced every few years, as directed by the manufacturer. Also keep it in your direct line of sight—it doesn’t have to be right in front of a vent, but it should be some place where you can see it without having to move your head much.
Carbon Monoxide Detectors
There are hundreds of CO detectors on the market. However, most of them are not well suited for aviation. They may not alert until CO concentrations reach over 100 ppm, or they may not have an alarm that’s audible in the loud cockpit of a general aviation airplane. Here are four options we have flown with and recommend.
Tocsin 4. This compact model features three alert modes—a 90 dB audio alarm, flashing red lights, and vibration—so you will notice it in the cockpit (trust me!). The built-in screen gives you a real time indicaton of CO ppm, but it’s still small enough to mount almost anywhere. You can use the sturdy clip to keep it attached to a seat belt or mount it to the panel so it’s in view. The default low alarm is set at 35 ppm and the high alarm is set at 100 ppm. It also has a TWA setting for 8 hours, but this is less important unless you’re troubleshooting a persistent problem. More Info
The Tocsin 4 features three alert modes—a 90 dB audio alarm, flashing red lights, and vibration.
Forensics 2.0. This new version of the Forensics Carbon Monoxide Detector boasts brighter LED alarms, a soft rubber touch feel, a larger LCD display, and a key ring for battery replacement. The CO alarms are set at 9 ppm with red LED and 25 ppm with an audible buzzer sound (70 dB) to ensure maximum protection. These alarm levels were chosen based on recommendations from the World Health Organization and Environmental Protection Agency. The CO alarm includes smart detection algorithms designed in the USA. Unlike regular CO alarms for the home, this detector is designed to detect CO levels at an early stage before the situation becomes dire.
Unlike regular CO alarms for the home, the Forensics 2.0 is designed to detect CO levels at an early stage.
ForeFlight Sentry Plus. This all-in-one ADS-B receiver does more than just receive weather and traffic. It also features a built-in CO detector that alerts pilots via a loud audio alarm, a flashing red light on the device itself, and a pop-up alert in the ForeFlight app. This makes Sentry Plus a solid safety tool for every flight, and it can be mounted out of the way if necessary.
The Sentry Plus features a built-in CO detector that alerts pilots via a loud audio alarm, a flashing red light on the device itself, and a pop-up alert in the ForeFlight app.
Lightspeed Delta Zulu Headset. The Lightspeed Delta Zulu is the first headset with a built-in carbon monoxide detector and alerting system. It works right out of the box: simply put the headset on and press the power button—you’ll automatically get audio alerts anytime unsafe levels of CO are detected. Because you use a headset on every flight, you’ll enjoy always-on protection.
Because you use a headset on every flight, you’ll enjoy always-on protection with the Lightspeed Delta Zulu.
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