SLIDE 5
FUEL TANK SAFETY
Learning Objectives
1. FTS History & Background
o Understand key past incidents (like TWA 800) that led to stricter FTS regulations.
o Learn how safety issues in the fuel tank system evolved over time.
2. Theoretical & Practical Knowledge
o Know how fuel systems work and the risks of fuel vapor ignition.
o Apply theory to real-life scenarios and maintenance tasks.
3. Application of Knowledge
o Combine technical knowledge with safety procedures to maintain FTS
compliance.
o Think critically and act safely during inspections or repairs.
4. Impact on Aircraft & Maintenance
o Learn how FTS issues affect aircraft design and maintenance schedules.
o Understand why strict procedures are in place to prevent ignition risks.
5. Identifying FTS Components
o Use manufacturer manuals and drawings to locate parts subject to FTS.
o Focus on pumps, wiring, bonding, and components inside fuel tanks.
6. Service Bulletins & Airworthiness Directives
o Understand how to interpret and implement SBs and ADs related to FTS.
o Learn planning and documentation processes to ensure compliance
SLIDE 18
FTS Initiatives
After fuel tank explosion incidents, FAA and JAA/EASA introduced major FTS safety
initiatives.
Based on SFAR 88, which set standards to prevent future fuel tank explosions.
1. Ignition Prevention
o Prevent any possible ignition sources inside the fuel tank (e.g., electrical sparks,
hot surfaces).
o Includes better wiring, bonding, shielding, and inspections.
2. Flammability Reduction
o Reduce the chance of flammable vapors forming.
o Example: using Nitrogen Inerting Systems to reduce oxygen in tanks.
3. Improved Maintenance
o Update practices to reduce risks introduced during inspections or repairs.
o Ensure safety is maintained after maintenance is done.
4. Instructions for Continued Airworthiness (ICA)
o Clear documentation from manufacturers to ensure long-term FTS compliance.
o Includes AMM tasks, inspection intervals, and design limitations
Training Requirements – SFAR 88
Mandatory training for all maintenance staff involved with fuel system tasks.
Aims to raise awareness, improve practices, and prevent future incidents.
SLIDE 21
Factors of FTS Explosions
Trainer Notes – Fuel Vapour Ignition Basics
1. What Causes Ignition?
o Ignition needs three things: fuel vapor, oxygen, and an ignition source (spark,
flame, or hot surface).
2. Flash Point
o The flash point is the lowest temperature at which a liquid gives off enough
vapor to ignite in air.
3. Fuel-Air Mix
o For combustion to happen, the vapor concentration must be within explosive
limits—not too rich or too lean.
4. Explosion Severity
o The intensity of an explosion depends on:
Vapor concentration
Amount of fuel-air mixture available
5. Empty Tank Danger
o A nearly empty tank can be more dangerous:
More air space = more oxygen
Heat from nearby systems increases vapor
Creates a highly explosive mix
SLIDE 24
Ignition source
Possible Ignition Sources in Fuel Tanks
Common Ignition Sources:
1. Electrical Arcs – From faulty wiring or connectors.
2. Lightning Strikes – Can induce current in the fuel system.
3. Electrostatic Charging – From fuel movement or refueling.
4. Electromagnetic Interference (EMI) – Affects sensitive electrical components.
5. System/Wiring Failures – Short circuits or insulation breakdowns.
Mechanical & Thermal Sources:
6. Friction Sparks – From moving or rotating parts inside the tank.
7. Mechanical Contact – Components rubbing or colliding during failure.
8. Hot Surface or Auto-Ignition – Overheated parts (e.g., pumps or probes) reaching ignition
temperature.
Environmental Factors:
Tank pressure, temperature, and fuel sloshing/spraying can increase ignition risk.
Vapors are most dangerous when tanks are partially full and heated.
SLIDE 25
Other Ignition Sources
1. Pneumatic System Failures
Air duct leaks near fuel tanks can cause hidden heating of tank surfaces.
If heat exceeds auto-ignition temperature, fuel vapors may ignite—especially in empty
or low-fuel tanks.
2. Electrostatic Charge Buildup
Non-conductive foam (e.g., polyurethane) can accumulate static charge inside tanks.
Fuel spraying from:
o Poorly designed refueling nozzles
o Fuel pump return lines
...can create charged mist, increasing spark risk.
3. Electrical Transients (Lightning, EMI, HIRF)
Can induce voltage in conductive components like:
o Fuel tank structure
o Plumbing
o Wiring and probes (especially fuel quantity system)
Risk of arcing or sparking inside tanks if shielding or bonding is inadequate.
Key Takeaway for Trainees:
These hazards can occur without visible damage—proper inspection, bonding, shielding, and
system design are critical to fuel tank safety.
SLIDE 27
Flammability Reduction
Purpose of AC 25.981-2A
Provides guidance for complying with FAA standards to reduce fuel tank flammability
in transport aircraft.
Main Objectives:
1. Limit Flammability Time
o Reduce the amount of time fuel tanks contain flammable vapors (especially
center wing tanks).
o Use of systems like Nitrogen Inerting to displace oxygen.
2. Hazard Mitigation
o If ignition occurs, design must minimize damage and prevent explosion.
o Examples: shielding, venting, and improved tank structure.
Key Takeaway for Trainees:
The focus is on preventing vapor ignition and limiting consequences if it happens—both are
vital to aircraft safety and airworthiness compliance.
SLIDE 33
Airworthiness limitations
What Are AWLs?
Mandatory tasks to prevent ignition sources in fuel tanks.
Includes:
o CDCCLs (Critical Design Configuration Control Limitations)
o Inspections
o Maintenance procedures
Why Are They Important?
Required by Amendment 25-102 to prevent ignition hazards from developing over the
aircraft’s life.
Ensure safety is maintained during maintenance, repairs, or modifications.
Where Are They Documented?
Must be included in the Airworthiness Limitations section of the ICA (Instructions
for Continued Airworthiness).
Operators and maintenance staff must strictly follow these limitations.
Key Takeaway for Trainees:
Always refer to and comply with AWLs to maintain fuel tank safety—they are legally
mandatory and critical to airworthiness.
SLIDE 34
Airworthiness limitations
Types of Fuel System Airworthiness Limitations
Three Main Types:
1. Inspections
o Specific tasks with defined intervals (e.g., every 10 years).
o Ensure ongoing safety and condition of fuel system components.
o
2. Procedures
o Maintenance or operational procedures related to fuel system safety.
o May have specified intervals or conditions for execution.
o
3. CDCCLs (Critical Design Configuration Control Limitations)
o No set interval—these are configuration limits to protect critical design features.
o Prevent unauthorized changes that could introduce ignition risks.
o Often require placards or labels to identify critical features.
Additional Notes:
Some manufacturers split AWLs into:
o ALIs (Airworthiness Limitation Inspections & Procedures)
o CDCCLs (Configuration Controls)
CDCCLs often refer to other manuals like AMM or SWPM for detailed instructions.
Key Point for Trainees:
Understanding these types helps ensure the right maintenance actions are done when required
and without altering critical safety features.
