8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 1/88
1
Government of Bermuda DCAFuel Tank System Safety
Module 6
Len Arnot-PerrettAVISA
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 2/88
2
fuel tank system safety
Overview for managers of
airworthiness & maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 3/88
3
Welcome to the course
Course objectives Familiarise candidates with the elements of
Fuel Tank System Safety Issues Enable candidates to understand the historical
background and elements requiringconsideration in relation to fuel system safety
Equip candidates to understand and use thelanguage of fuel system safety issues
Allow candidates to understand and interpret
fuel system safety issues from regulatory andmanufacturer’s maintenance publications
Satisfy Parts M & 145 Amendments on fuelsystem safety
Note: this course covers level 1 requirements 3
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 4/88
4
Fuel tank system safety – the beginning?
4
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 5/88
5
Fuel tank system safety – the beginning?
TWA Flight 800 crashed at 20.30 on July 17 1996
5
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 6/88
6
Fuel tanks system safety – the end?
6
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 7/88
7
Fuel tank system safety – introduction for managers of
airworthiness & maintenance
Neither the beginning nor the end!
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 8/88
8
The investigations surrounding the accident
led to many basic design and certificationassumptions about installed fuel tanksystem safety to be substantially revised.
What have design and certificationassumptions got to do with in-servicecontinuing airworthiness managementand maintenance of aircraft?
8
Fuel tank system safety – introduction formanagers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 9/88
9
All of the continuing airworthiness processes
could be affected!
“covers all of the processes ensuring that at
any time in their operating life, all aircraftcomply with the airworthiness requirements in
force and are in a condition fit for safeoperation.”
Regulation 2042/2003 – Article 2 - Definitions
9
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 10/88
10
• AD
• Flight Manual• Modifications
• Repairs
• MMEL
• Life Limits
• AirworthinessLimitations
• C of A
• Records
• MaintenanceProgramme
• Maintenance
Standards
• Reliability Programme
• CertificationMaintenanceRequirements
• Weight & Balance
• Occurrence Reporting10
Fuel tank system safety – introduction formanagers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 11/88
11
• As you can see, these processes arethose associated with the operation,
continuing airworthiness and maintenance
of aircraft.
In the global fleet of aircraft – all of theprocesses have been affected
11
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 12/88
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 13/88
13
Or has it been safe?
13
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 14/88
14
Or has it been safe?
14
Fuel tank system safety – introduction formanagers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 15/88
15
Or has it been safe?
15
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 16/88
16
Or has it been safe?
A global review of in-service fuel tank
safety data demonstrated that fuel tank
safety does not meet contemporarystandards for system safety targets
16
Fuel tank system safety – introduction for managers of
airworthiness & maintenance
F l t k t f t
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 17/88
17
Fuel tank system safety – introduction for managers ofairworthiness & maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 18/88
18
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
In the period 1960 – 1996 – 17 fatality
events due to fuel tank system events!
Let us consider a sample – relevant totoday.....
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 19/88
19
• 8 December 1963 – Pan Am B707
• 9 May 1976 – Iranian Air Force B747
• 22 August 1985 – BA Air Tours B737
• 11 May 1990 – Philippine Air Lines B737
• 17 July 1996 – TWA 800 B747
• 3 March 2001 – Thai Airways B737• 5 September 2001 – BA B777
• 20 August 2007 – China Air B73719
Fuel tank system safety – introduction formanagers of airworthiness & maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 20/88
20
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
Is this a Boeing problem?
Not exclusively!
Boeing had flown approximately 70% of
large commercial airplane flights in 2000
It is a matter of exposure then.
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 21/88
21
1990 - B-737-300
Manila, Philippines
1996 - B-747, TWA
800, JFK
2001 - B-737-400
Bangkok Thailand
Almost new airplane 25 year old airplane 10 year old airplane
Air Conditioning Packsrunning during Ground
Operations
Air Conditioning Packsrunning during Ground
Operations
Air Conditioning Packsrunning during Ground
Operations
Empty CWT explosion
during pushback fromgate
Empty CWT explosion
during climb
Empty CWT explosion
minutes afterrefueling
CWT pumps operating
at time of explosion
CWT pumps operating
at time of explosion
8 fatalities 230 fatalities 1 fatality
Jet-A fuel, approx. 95
degree F ambient
temp.(35’C)
Jet-A fuel, approx.
120 degree F tank
temp.(49’C)
Jet-A1 fuel, approx.
97 degree F ambient
temp.(36’C)
NO IGNITION SOURCE
IDENTIFIED
NO IGNITION SOURCE
IDENTIFIED
NO IGNITION SOURCE
IDENTIFIED21
Fuel tank system safety – introduction formanagers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 22/88
22
Fuel tank system safety – introduction formanagers of airworthiness &
maintenance
0
1
2
3
4
5
6
7
8
9
10
1990 1995 2000 2005 2010 2015 2020
Year
C u m u l a t i v e
A c c i d e n t s
Manila
New York
Bangkok
ARAC ~10E-8
10E-9
Extremely improbable -
not anticipated to occur in the life of
the fleet
Systemic Change Needed22
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 23/88
23
CS25.1309 AMC 1309CS25.1309 AMC 1309
Figure 1 - Relat ionship bet w een Probabi l i t y and
Sever i t y o f fa i lure Condi t ion
JAR 25
PROBABILITY
CLASSIFICATION
OF FAILURECONDITIONS
PROBABLE IMPROBABLE
EXTREMELY
IMPROBABLE
MINOR MAJOR HAZARDOUS CATASTROPHIC
100 10-3 10-5 10-7 10-9
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 24/88
24
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
Investigations revealed that the CWT were
heated to a greater extent than previouslybelieved - 140°f peak recorded on one
aircraft type
High temperature leads to high flammability
High flammability means that ignition source
energy required to initiate event is muchlower than reviousl calculated
Fuel tank system safety introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 25/88
25
Ignition
Oxygen Fuel VaporHeated tanksFlammability Reduction
“Prevent fuel system
accidents through ignition
source elimination and
flammability reduction”
25
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
F l t k t f t i t d ti
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 26/88
26
Main Tanks 2-4%Tail Tanks 2-5%
Body Tanks• Pressurized <5%• Un-pressurized >20%
Heated Center Wing Tank 15-30%Un-heated Center Wing Tanks 2-6%
Fuel Tank Flammability Exposure Worldwide Fleet Average
26
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 27/88
2727
Fuel Tank Safety – Module 2Flammability Envelope
vs. Ignition Energy, Flash Point and O2
Level
0
10
20
30
40
50
-50 0 50 100 150 200Temperature Deg F
A l t i t u d e
1 0 0 0 ' s f t .
LFL
UFL
Heated CWTProfile
Unheated WingTank Profile
Pointer
Flammable Zone
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 28/88
28
Fuel tank system safety – introductionfor managers of airworthiness &
maintenanceReinvestigation of design certification
standards also led to need to review all
tank installations – including un-heatedtanks
• Special Federal Aviation Rulemaking –
SFAR 88 – FAA AC 25.981.1(b)
– FAA AC 25.981.2
• JAA INT/POL/25/12
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 29/88
29
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
SFAR 88
Initiated in 2001 – assessment stage
Existing fleet in Europe and North America
All basic airplane design configurations andsupplemental Designs affecting the fuel
system
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 30/88
F l k f
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 31/88
31
Fuel tank system safety – introduction for managers of
airworthiness & maintenance
Full reinvestigation of design – fuel tank
systems – require DAH to identify FuelTank Airworthiness Limitation Items
including
• Critical Design Configuration Control Limitations
• Airworthiness Limitation – inspections
• Airworthiness Limitation – modifications
• -
F l k f i d i
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 32/88
32
SFAR 88 (AC 25.981.1c) & JAA TGL 47 andINT/POL/25/12
Critical Design Configuration Control Limitation(CDCCL):
A fuel system feature the design integrity of whichmust be maintained to ensure that an unsafecondition does not develop. Features in an
aircraft system or component. May exist in fuelsystem but may also be features in systems orassemblies that interact or cross-couple with
fuel systems32
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 33/88
33
SFAR 88 (AC25.981.1c) & JAA TGL 47 andINT/POL/25/12
Examples of CDCCL:-Bonding feature attaching to component and
tank
Separation of fuel gauge wiring from other high – power wiring
Fuel pump configurationWire support for high power wiring near to tank
We will later look at some characteristic CDCCLfrom TC Holders
33
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
Fuel tank system safety
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 34/88
34
SFAR 88 (AC25.981.1c) & TGL 47 andINT/POL/25/12
Fuel Tank System Airworthiness Limitation
Items (ALI)Fuel System Mandatory Instructions – can
include
Design changes
Maintenance
InspectionsProcedures 34
Fuel tank system safety – introduction for managers ofairworthiness & maintenance
F l k f
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 35/88
35
SFAR 88 (AC25.981.1c) & TGL 47 andINT/POL/25/12
Fuel Tank System Airworthiness Limitation Items
(ALI)Those items necessary to ensure that
Unsafe conditions do not arise in the fuel
system throughout the service life of theairplane
ALI to be mandated by AD and included in theAirworthiness Limitations Section of ICAW
35
Fuel tank system safety – introduction for managers ofairworthiness & maintenance
F l t k t f t i t d ti
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 36/88
36
SFAR 88 (AC25.981.1c) & JAA TGL 47 andINT/POL/25/12
For the identification and management of CDCCL
Related tasks highlighted by TCH in AMM/CMM
Airworthiness management procedures put in placeEnsure features are protected during repair/changes
Ensure maintenance organisation is aware
Implement training programmes
Remember, the feature itself may not be directly related
to the fuel system and also may be at component level e.g. fuel pump! 36
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
F l k f i d i
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 37/88
37
Fuel tank system safety – introductionfor managers of airworthiness &
maintenanceIdentification and management of CDCCL – at a
component level
37
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 38/88
38
SFAR 88 (AC25.981.1c) & JAA TGL 47 andINT/POL/25/12
For the identification and management of CDCCL
If fuel pump configuration is to beidentified as a CDCCL, how will theoperator control the CDCCL?
Pool parts
Component suppliers
38
y yfor managers of airworthiness &
maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 39/88
39
SFAR 88 (AC25.981.1c) & JAA TGL 47 andINT/POL/25/12 – continued – 24
For the identification and management of CDCCL
Fuel Pump CDCCL management:-
This will be a challenge for the operatorsEASA Part 145 Form 1, FAA 8130-3
Contracts will need to specify CDCCL
managed and complied with during MROactivity – box 13(?)
CAME procedure in place
Maintenance procedure for MRO39
y yfor managers of airworthiness &
maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 40/88
Fuel tank system safety –
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 41/88
41
An ALI could be a modification/change:-
EASA AD 2006-0191
A330-200, A340 – 200/300 aircraft
Air Conditioning – prevention against fuel
explosion risks – installation of heatshields in belly faring
HO241
Fuel tank system safety introduction for managers ofairworthiness & maintenance
Fuel tank system safety
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 42/88
42
Boeing Airplane MPD already published withALI/CDCCL
e.g. B767 MPD
AWL No. 28-AWL-01: Task – ALI – detailed inspection
of wire bundles over CWT – 12y/36000HAWL No. 28-AWL-02: CDCCL – External Wires over
CWT – maintain existing wire bundle routing and
clamping
42
Fuel tank system safety – introduction for managers ofairworthiness & maintenance
– for managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 43/88
4343
for managers of airworthiness &maintenance
Fuel tank system safety –
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 44/88
44
Boeing Airplane MPD already published with
ALI/CDCCL
e.g. B767 MPDAWL No. 28-AWL-03: CDCCL – Lightning protection –
Engine fuel feed line - verify electrical fay surface
bond from bulkhead fitting to structure – 0.5 milliohmsor less
AWL No. 28-AWL-04: CDCCL – Lightning protection –
Hydraulic line fuel tank penetration – bond checks onheat exchanger and lines – to structure and in-lineconnectors
44
Fuel tank system safety introduction for managers ofairworthiness & maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 45/88
45
Operator required to maintain integrity ofCDCCL throughout operation and
maintenance of airplane.This could be a challenge…
• Airworthiness management processes – including modification, repair & ARC
• Maintenance procedures
• Component maintenance
45
Fuel tank system safety introductionfor managers of airworthiness &
maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 46/88
46
Fuel tank system safety – introductionfor managers of airworthiness &
maintenance
FAA Aviation Rulemaking Advisory
Committee – ARAC studies heating effectson fuel Tanks 1998.
External heat sources to be avoided – forthe future!
Flammability suppression guidance
developed
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 47/88
47
Fuel tank system safety introductionfor managers of airworthiness &
maintenance
Industry Fuel Tank System Safety
programme commenced in 1998
Sample surveys of aircraft in-service fleets
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 48/88
48
Industry Fuel System Safety ProgrammeSurvey was not conclusive but there were
findings
Bonding provisions missing Swarf and contamination in tanks Damaged components
Evidence of overheated pumps Wiring problems Vent systems incorrectly assembled
48
Fuel tank system safety introductionfor managers of airworthiness &
maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 49/88
49
Bonding straps in tanks
Straps missing, broken, looseStraps frayed/worn as a result of wing movement
Corroded straps and attachment points
Lightning strikes have resulted in the loss of aircraft due topoor bonding!
Poor/missing bonds are often caused by maintenanceerror! You may be only 1 fault away from an unsafecondition!
49
for managers of airworthiness &maintenance
F l t k t f t i t d ti f
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 50/88
50
Another Survey finding that was very relevantto the future was the relatively high level ofmaintenance error induced occurrences in fueltank system installations
UK study of B747 occurrences showed 16%maintenance error correlation over a 20 yearperiod!
Another relevant finding was the comparativeseriousness of the fuel tank system relatedoccurrences
50
Fuel tank system safety – introduction formanagers of airworthiness & maintenance
Fuel tank system safety – introduction for
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 51/88
51
Maintenance error? Serious occurrences?
Most regulatory systems had provisions forflying control system maintenance to reducethe likelihood of maintenance error inducedoccurrencesRequired Inspection ItemsDuplicate Inspections
Independent Inspections
Perhaps we need to build similar defences for
fuel system maintenance? 51
Fuel tank system safety introduction formanagers of airworthiness &
maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 52/88
52
Fuel tank system safety introductionfor managers of airworthiness &
maintenance
Another finding was that Zonal Inspection
Programmes were not proving as effectiveas they ought to be
Problems with• Mechanic licensing schemes
• Training of Inspectors at MRO
• Poor maintenance at component organisations
Fuel tank system safety –
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 53/88
53
Fuel tank system safety introduction for managers of
airworthiness & maintenanceMechanic licensing schemes, Training of Inspectors at
MRO
Poor maintenance at component organisations? Licensing schemes are not able to adequately address all
inspection standards and licensing schemes do not exist
at a component level e.g. Zonal Inspection standard could be • General Visual
• Surveillance
What do they mean? How are they applied?
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 54/88
54
MSG3 Definition:
General Visual Inspection:-
A visual examination from arms length that will
detect obvious unsatisfactory conditions/ discrepancies. This type of inspection may require
removal of fillets, fairings, access panels / doors,
etc. Workstands, ladders etc. may be required togain proximity.
54
Fuel tank system safety introductionfor managers of airworthiness &
maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 55/88
55
Fuel tank system safety introductionfor managers of airworthiness &
maintenance
Mechanic licensing schemes, Training of Inspectors at MRO
Poor maintenance at component organisations?
General Visual Inspection requires the identification of obvious signs of deterioration: the Part 66/A&P examinations are not able to test the applicants
knowledge to that extent!
This determination requires visual parameters…….
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 56/88
56
Fuel tank system safety introductionfor managers of airworthiness &
maintenanceMechanic licensing schemes, Training of Inspectors at
MRO
Poor maintenance at component organisations?
How are the MRO’s meant to deal with this?
Part 145 requires organisation training for issue of authorisations – this would include the need to ensure that relevant inspection standards were covered at an airplane as well as a component level!
• Continuation training
• Pictures of inspection findings
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 57/88
57
y yfor managers of airworthiness &
maintenance
Mechanic licensing schemes, Training of Inspectors at
MRO Poor maintenance at component organisations?
Some of the problems uncovered were probably due to poor installation standards
during modification activities!
Fuel tank system safety – introductionf f i thi &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 58/88
58
for managers of airworthiness &maintenance
Fuel tank system safety – introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 59/88
5959
introduction for managers ofairworthiness & maintenance
Fuel tank system safety – f f
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 60/88
60
introduction for managers ofairworthiness & maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 61/88
Fuel tank system safety – introduction for
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 62/88
62
Wiring problems were being investigated bythe Ageing Transport Systems Rulemaking
Advisory Committee (ATSRAC) study goingon in parallel with SFAR 88
ATSRAC set up by FAA to study ageingeffects in systems – focuses on wiringsystems
Produces rule making Enhanced
Airworthiness Programme for AircraftSystems/Fuel Systems – (EAPAS)6262
managers of airworthiness &maintenance
Fuel tank system safety – introductionf f i thi &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 63/88
63
for managers of airworthiness &maintenance
2000 - ARAC 2 set up to look into
requirements for Flammability ReductionSystems – FRS – to significantly reduce the development of flammable vapours
Workable and economically viable on-board
system developed by FAA TechnicalCentre
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 64/88
64
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004+
Manila New York Bangkok
NTSB
recommendations
FAA Task to Industrybased on NTSB
Recommendations
Industry Fuel
SystemsSafety
Program
SFARNPRM
SFAR 88Assessment
ARACFlammability
ReductionStudy
ARACInertingStudy
SFAR 88Implementation
NGSDevelopment
Industry and Regulatory consensus: Reducing flammabilitywould provide major benefit to enhancing fuel tank safety
64
for managers of airworthiness &maintenance
Fuel tank system safety – introductionf f i thi &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 65/88
65
What has happened since 2004?
Things have moved slowly!
65
for managers of airworthiness &maintenance
Fuel tank system safety –introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 66/88
66
March 2007 – EASA Agency Decisions 2007/01R,2007/02R and 2007/03R issued on Fuel systemsafety
Part 145 organisations – component and
airplane levelPart M airworthiness Management
organisations
Part 66 Licensing
NPA 2008-19 to change rules still not closed!
66
introduction for managers ofairworthiness & maintenance
Fuel tank system safety – introduction
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 67/88
67
for managers of airworthiness &maintenance
2007 – Flammability Reduction System
certified by FAA/EASA for Boeing products
Boeing introduce production cut-ins forcurrent models and proposals for fitmentto existing fleets
Fuel tank system safety –
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 68/88
68
introduction for managers ofairworthiness & maintenance
Why bother with FRS?
FAA estimate that in order to obtain the
order of magnitude change required toobtain the required level of safety – Ignition Source Suppression – on its own –
required to be at least 75% effective.
Fuel tank system safety – introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 69/88
69
introduction for managers ofairworthiness & maintenance
• Malaysian Register 727 tank explosion
due to wiring failure in wing – fuel pumpsupply wire.
• B777 CWT fuel leak during TO – panel left
off after maintenance
• Airbus FQIS lightning protection failures
Ignition source suppression cannot be
guaranteed to be wholly effective!
Fuel tank system safety – introductionfor managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 70/88
70
October 22 2007 FAA issue final rule ‘’EnhancedAirworthiness Programme for Airplane
Systems/Fuel Tank Safety (EAPAS/FTS)’’
This rulemaking was part of the ATSRACrulemaking relating to airplane wiring systemsand included fuel tank system installations
70
for managers of airworthiness &maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 71/88
71
Fuel tank system safety – introductionfor managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 72/88
72
What is EAPAS and what has EAPAS got to do with Fuel Tank System Safety?
Wiring problems connected with Fuel Tank Safety were delegated to Ageing
Transport System Rulemaking Advisory Committee – ATSRAC – who developed
EAPAS.72
for managers of airworthiness &maintenance
Fuel tank system safety – introductionfor managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 73/88
73
July 21 2008 FAA issue final rule‘’Reduction of Fuel Tank Flammability inTransport Category Airplanes’’
73
for managers of airworthiness &maintenance
Fuel tank system safety –i t d ti f f
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 74/88
7474
introduction for managers ofairworthiness & maintenance
Fuel tank system safety – introductionfor managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 75/88
75
What do the FAA Rules do and will theyaffect me?
75
for managers of airworthiness &maintenance
Fuel tank system safety –introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 76/88
76
Any differences between European/USimplementation could affect
Insurance Premiums
Lease arrangements – operator/operator
Lease arrangements – operator/leasing company
Transfer/Export of Airplanes
Airbus/Boeing will be required to meet FAA productioncut-in targets – production aircraft will be standard
In addition - an operator operating an airplane inaccordance with Part 129 would obviously be affected!
76
t oduct o o a age s oairworthiness & maintenance
Fuel tank system safety –introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 77/88
77
The FAA final rule RIN 2120-A123 simultaneouslyintroduces a number of FAA rule changes
applicable to US Design Approval Holders(DAH) and operators of US Register airplanes
Introduces Part 26 for DAH – to harmonise with
EASA(?)
Part 121 - Domestic, Flag and Supplemental Operations
Part 125 – Airplanes seating cap. 20+ pax. Or
payload>6000lbs.
Part 129 – Foreign Air Carriers and Foreign Operatorsof US Register Airplanes Engaged in Common Carriage
77
introduction for managers ofairworthiness & maintenance
Fuel tank system safety – introductionfor managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 78/88
78
A detailed knowledge of the FAA rulemaking isnot necessary for a non-US register aircraftoperator
We include a brief summary of the rule making
however since there will almost certainly be aneed to understand the basics due to thecontinuing movement of aircraft ownership
across international boundaries
78
for managers of airworthiness &maintenance
Fuel tank system safety –introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 79/88
79
FAA Final Rule summary
Introduction of FAR 26 requirements – fuel
tanks within the fuselage contour – flam>7%, allother tanks flam>7% DAH to assess fleet average flammability exposure – to be
complete within 150 days following 19 September 2008 Fleet average flammability exposure target <7%
Flammability Reduction Means (FRM) to be identified ifexposure>7% fuselage contour tanks (AC 25.981-2)
Ignition Mitigation Means (IMM) to mitigate ignition sources intanks (AC 25.981-1)
September 20 – 2010 DAH to submit FRM ICAW including
CDCCL September 20 – 2010 DAH to submit FRM ALI 79
introduction for managers ofairworthiness & maintenance
Fuel tank system safety – introduction for managers
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 80/88
80
FAA Final Rule summary
Introduction of FAR 26 requirementsALI – Airworthiness Limitation Items
CDCCL – Critical Design ConfigurationControl Limitations
80
y y gof airworthiness & maintenance
Fuel tank system safety – introductionfor managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 81/88
81
FAA Final Rule summary
Part 121 – by September 20 2010 – new
production airplanesFRM, to be operational
Ignition Mitigation Means (IMM) to beimplemented
B747 Series Airbus A 318, A 319,
A320,A321 seriesB737 Series Airbus A 330, A 340
Series
B777 SeriesB767 Series 81
for managers of airworthiness &maintenance
Fuel tank system safety –introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 82/88
82
FAA Final Rule summary
Part 121 – Retrofit
50% of US operator’s fleet to have installations
required by Part 26 by 2014100% of US operator’s fleet to have installations
required by Part 26 by 2017
Installations to be operational
The flammability targets will effectively result in FRM
for most Airbus and Boeing types in current airlineuse 82
introduction for managers ofairworthiness & maintenance
Fuel tank system safety – introductionfor managers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 83/88
83
FAA Final Rule summary
Part 121 – Maintenance ProgrammesType specific ALI and CDCCL mandated by AD
Maintenance Programmes must be revised to take
into account modifications required by Part 26Compliance dates for Maintenance Programme
changes may be extended subject to use of ground
air conditioning for B737, 747, 757, 777, 767 andA300, A310, A318, A319, A320, A321, A330, A340.
83
for managers of airworthiness &maintenance
Fuel tank system safety –introduction for managers of
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 84/88
84
29 May 2008 EASA issue NPA No 2008-16‘’Fuel Tank Safety – incorporation of the
Critical Design Configuration ControlLimitations (CDCCL) into Acceptable Meansof Compliance for Part-M, Part-145 and Part
66’’
17 July 2008 EASA issue NPA N0 2008-19‘’Fuel tank flammability reduction’’ – this isequivalent to FAA FAR 25 and AC 25.981-1and AC 25.981-2 – this is a design and certification
code for future airplanes and is not retrospective - FAA FAR 26 is! 84
t oduct o o a age s oairworthiness & maintenance
Fuel tank system safety – introduction formanagers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 85/88
85
The EASA change to CS 25 will not result in
retrospective implementation to existing
fleets and will probably only come intoeffect for A350 and B787
85
managers of airworthiness &maintenance
Fuel tank system safety – introduction formanagers of airworthiness & maintenance
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 86/88
86
managers of airworthiness & maintenance
EASA rule making will not implement
requirement for retro-fit of flammabilityreduction systems whilst FAA rule will.
Fuel tank system safety – introduction formanagers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 87/88
87
managers of airworthiness &maintenance
EASA has issued AD’s for Airbus fleet ALI
and CDCCLWill result in need for changes in
maintenance and airworthiness
management organisations – Part 145 andPart M
Fuel tank system safety – introduction formanagers of airworthiness &
8/8/2019 6. bermuda fts
http://slidepdf.com/reader/full/6-bermuda-fts 88/88
Changes to airworthiness management andmaintenance procedures
Task card development Maintenance Procedures including verification tasks –
tank closure
Repairs/changes Maintenance Programme development
ARC issue
MEL management Occurrence reporting standards
Training
managers of airworthiness &maintenance
Top Related