Aircraft Fuel Leaks Repair Or Face The Consequences
Overview
Overview
Aircraft fuel leaks are serious business. It is imperative to rectify the situation as quickly as possible; otherwise, you run the risk of wasting expensive fuel or even more severe issues such as in-flight fuel starvation to your aircrafts engine(s).
Determining the cause of an aircraft fuel leak is tricky. It requires solid knowledge and experience, plus enough time to perform appropriate investigative work. Nevertheless, there are some more commonly known causes.
Common Causes of Aircraft Fuel Leaks
Among the common causes for aircraft fuel leaks are stress and/or structural damage, corrosion and sealant degradation. Economic factors often require aircraft to be kept in service longer and this, combined with the fuel system inspection practices of some commercial operators, often aggravates the problem. It is therefore important to have a robust maintenance process ensuring flight safety.
Metal fatigue and structural damage, caused either by hard landings or high cycle times, can also be a common source of aircraft fuel leaks. Hard landings can have a negative effect on fuel system sealants, causing them to lose their bond with the aircraft. Fuel system sealants are also affected by weather, particularly in the case of aircraft parked on the flight line. However, it is important to recognize that even aircraft kept in hangars can be affected.
Before the leak can be repaired, the source must first be identified. The aircraft mechanic should note where the leak appears. If the leak appears relatively far from the fuel system, it may require a diligent search to trace it back to its origin. The mechanic should also take note of when the aircraft fuel leak occurs - leaks that occur at all fuel levels could be in either the tank bottom or the fuel lines, while a leak that occurs only while the tank is full is more likely to be in the tank itself.
Aircraft Fuel Leaks due to Corrosion
Corrosion in aircraft fuel systems is often caused by bacteria, cladosporium resinae and pseudomonas aeruginosa, which live in the water-fuel interface inside fuel tanks. These bacteria can enter the fuel system through contaminated fuel, standing water in sump bottoms or even through the tank vents.
As these colonies spread, they form dark-colored mats with a consistency similar to gelatin. The bacteria can corrode plastic and rubber components by eating the hydrocarbons out of them, while their waste products include acids, which will corrode any metals that they come into contact with, both of which can lead to aircraft fuel leaks.
Outward signs of a bacterial infestation include clogged filters, dark slimy mats on the bottoms of tank surfaces and a rotten egg smell caused by hydrogen sulfide, another waste product. While there are not currently any products that will completely prevent bacteria in fuel tanks, there are several additives which can be used to retard their growth.
Regardless of the cause of aircraft fuel leaks, repairs are required in order to ensure the safety of those flying the aircraft.
Aircraft Fuel Leak Repair
A sound fuel system maintenance program performed by an experienced and qualified mechanic is the first step to aircraft fuel leak repair. As stated above, before repairs can be made the source of the leak must first be identified. This can be a tedious and timely process because the source of the leak can be a considerable distance from the area where the leak is noticed.
Identifying the type of fuel system through careful review of the maintenance manual will give the mechanic information required to gain access to the fuel tank. There are three types of fuel tanks:
Integral or wet wing, in which the tank is part of the aircrafts wing structure.
Fuel cell, which is a rubber bladder inside the wing.
Built-up metal or fiberglass, which resides inside the wing.
Each of the three types has different potential points for leaks. Therefore, the mechanic must know which fuel tank system he is dealing with and how to approach the inspection and repair process.
If the aircraft fuel leak is found to originate in the fuel tank, the next step is to remove the tank, when possible. Integral tanks cannot be removed as they are part of the wing and must be repaired in place. Other fuel tank types should be removed for repair. All aircraft fuel leak repairs should be performed by following the instructions from the manufacturers maintenance manual.
If the leak is found in other parts of the
aircraft fuel system, such as a connection between lines or at the filter or pump, then the affected parts should be removed following the manufacturers instructions.
Once repairs are completed, the components must be properly reinstalled, taking care not to undo the repair as well as avoiding the creation of any new leaks. Also, this is the time the mechanic should look for any new leaks.
Another integral point in the process to inspect for additional aircraft fuel leaks is during the initial fueling after the repair. Because leaks can take up to a day to present, it is a good practice to leave any fairings off the aircraft to make inspection easier. Once it is determined that there are no additional aircraft fuel leaks, the fairings can be reinstalled.
Aircraft fuel leak repair cannot be rushed. It takes time and diligence to ensure that the actual cause of the leak has been detected and corrected. Even once the repair is complete, additional time should be taken to confirm the repair and ensure that no new leaks have been created during to the installation process. Because aircraft fuel leaks can cost considerable time and money, it is important to take the appropriate time to perform and thorough investigation, making any needed aircraft fuel tank repairs. Doing so will ensure longer flight times moving forward.
by: Greg Katonica
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