High-quality Aircraft Fuel Cells Repair Starts With A Solid Inspection
Overview
Overview
Aircraft fuel cells require continual maintenance and often repair to maintain flightworthiness. Aircraft fuel is typically stored in three ways:
Metal tanks
Wet wing or integral tanks
Bladders or Fuel Cells
Aircraft fuel cells are very common and should be inspected regularly to keep them in good working condition. To understand more about appropriate maintenance and repair, it is prudent to first understand how fuel cells are made.
Aircraft fuel cells are manufactured by combining two or more layers of material that bonds two liners inner and outer. It is important that the inner layers are non-porous and resistant to fuel vapors. Outer layers protect the cell from the elements, including heat, ozone and humidity. If manufactured and maintained correctly, they can last as long as 20 years.
Start With an Aircraft Fuel Cells Inspection
Performing a thorough inspection is always the first step of any good maintenance process. By inspecting the aircraft fuel cells for general condition, security of attachment and evidence of leaks, the technician knows where to begin. In addition, a thorough examination of fuel tanks or fuel cell vent lines, fuel lines and sump drain attachment fittings is required.
After the baseline review, a more detailed inspection is required in order to determine the correct repair or maintenance.
First, de-fueled tanks should be purged of any explosive fuel/air mixtures. Use the manufacturers service instructions to ensure appropriate procedures. Once complete, the following can be used as a guide to complete the inspection:
1. Integral Tanks inspect the interior and seams for any sealant deterioration or corrosion, paying particular attention to the sump area. Check for leaks around skin joints, rivets, screws and bolts. Leaks are categorized as follows:
a. Slow Seep very slow fuel seepage in a small area that does not reappear in a short time frame.
b. Seep leak that appears in less than an hour after it was wiped dry.
c. Heavy Seep fuel leak that reappears immediately after it was wiped dry.
2. Internal Metal Tanks check the exterior and interior for corrosion and chafing. Also look for any dents or other anomalies. Sump areas are often an issue, so pay particular attention to these areas, particularly in cases where the sumps are made of cast material.
3. Flexible Aircraft Fuel Cells often referred to as bladders, these fuel cells should be inspected for cracking and other signs of deterioration. Bladders should not be allowed to dry out. Additionally, an inspection of the fuel tank caps for appropriate size and type should be performed, as well as determining if the O rings are in good condition.
Aircraft Fuel Cells Repair
After a thorough inspection,
aircraft fuel cells repairs can be initiated. The Federal Aviation Association (FAA) has approved some methods for repair. These are:
Heat Cured Factory Repairs
Air Cured Field Repairs
Coatings only some are approved.
Repairs must be made in accordance with
the manufacturers instructions, and ideally by a seasoned repair technician. Repairs can be made in a variety of methods, but in particular, after a welding repair there are important steps that must be taken.
Removal of Flux after Welding
If flux is not completely removed, corrosion can occur. Following these steps will ensure that all flux is removed after the aircraft fuel cell repair is complete:
1. Wash the inside and outside of the tank with plenty of hot water. Drain thoroughly.
2. Immerse the tank in either 5 percent nitric or 5 percent sulfuric acid solution. NOTE: If the tank cannot be immersed, then fill it with either solution and wash the outside with the same.
3. Leave the acid solution to remain in contact with the weld for approximately one hour. Rinse thoroughly with clean water.
4. Apply acidified 5 percent silver nitrate solution to a small amount of the rinse water used in the prior step. If a heavy white precipitate forms, the cleaning must be repeated.
Regardless of the type of repair performed, a complete
aircraft fuel cells inspection is the first step to ensuring thoroughness and completeness of repairs and maintenance procedures. Each repair should be executed using steps outlined by the manufacturer. To keep the aircraft flight ready and in good shape, perform regular inspections and maintenance. Aircraft fuel cells are no exception and a critical component of safety procedures.
by: Greg Katonica
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