Overview
Repair of an aircraft fuel system takes considerable time. However, as one of the three primary causes of grounding, fuel leaks are serious issues that must be addressed quickly. Not only can they cost money in precious fuel, but they can also create more serious problems such as fuel starvation to your aircraft's engines. Choosing to engage in a thorough, systematic approach to aircraft fuel leaks repair will save you time and money.
There can be multiple causes of fuel leaks including:
Stress
Structural defects
Degrading sealants.
Increase cycle times
In order to inspect for leaks, the mechanic must first know your aircraft fuel systems. Repair before the basic information is gathered will be a waste of time and money.
Aircraft Fuel Tanks Repair
Devising a sound fuel maintenance process is the first step to ensuring appropriate fuel leaks detection. There are several criteria that should be considered when detecting and repairing aircraft fuel leaks, including:
Properly identifying the cause of the leak
Identifying the type of fuel system
Careful tank inspection, including removal of panels
Performing the correct repair based on the fuel tank system
The first step, identifying the cause of the leak, is performed by an aircraft mechanic who recognizes the appropriate steps. These steps include noting where the leak appears, does it only occur when the tank is full, and does the leak stop when the tank is half full. Because a leak can travel a considerable distance before a drop actually appears, the mechanic will need to perform an aircraft fuel systems inspection.
Identifying the type of fuel system through careful review of the maintenance manual gives the mechanic information required to gain access to the fuel tank. There are three types of fuel tanks:
Integral (known as "wet wing") in which the tank is part of the aircraft's wing
Fuel cell, which is a rubber bladder inside the wing
Built-up metal or fiberglass tanks, which reside inside the wing
Each of the three types has potential points for leaks. The mechanic must know which fuel tank system he is dealing with and how to approach the inspection and repair process.
Careful inspection of the aircraft's fuel tanks is the next step. Removing the appropriate panels and thoroughly inspecting areas of the fuel tank can uncover the actual cause of the leak. This inspection requires both visual inspection and odor detection. While 100 low-lead aviation fuel is blue and will leave a blue stain when dry, jet fuel is colorless. However, it leaves a strong odor and is slow to dry making it detectable by a trained mechanic.
The mechanic will need to also make sure all connections and clamps are tight.
If the source of the leak is determined to be the fuel tank, the next step is to remove it to perform appropriate repairs. An integral tank cannot be removed as it is part of the aircraft's wing. Therefore, repairs must be made with it intact. The other fuel tank systems can be removed using the instructions in the aircraft's maintenance manual.
Once the aircraft's fuel tank repair is completed, the fuel system must be reinstalled according to the maintenance manual. Careful attention to detail when attaching panels is required. Also, the mechanic must look for new leaks during the installation process. It can take up to 24 hours for small leaks to be visible. Therefore, the fairings should be left off until the mechanic can determine there are no aircraft fuel leaks.
Repair of aircraft fuel systems cannot be rushed. This process takes time and careful investigation to ensure the actual cause of the leak is detected. Specialized training is often required for the mechanic to correctly repair fuel tank leaks. Once all the repairs are completed, more time is required for the mechanic to ensure no new leaks have occurred during the installation process. Furthermore, aircraft fuel tank repair often requires new sealant. To ensure no future leaks, it is important to follow the manufacturer's curing time recommendations which can add significantly to the time needed for repair.
Fuel leaks can cost considerable time and money. By taking the appropriate amount of time to thoroughly investigate and make aircraft fuel systems repairs, you will ensure longer flight times going forward.
Odor DetectGlobal Aircraft Service was founded by Greg Katonica and Paul McCain in 1998. Both have many years of experience in Fuel System Repairs. We are based at 4500 Claire Chennault, Addison, Texas 75001. We have a large facility that can accommodate most medium size corporate aircraft or we will travel to any site in the World.
Greg Katonica, President,
Global Aircraft Service, Inc.
4500 Claire Chennault Street, #103,
Addison, TX 75001
Ph: 972-267-6650