Aircraft Fuel System Safety Program Report

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1.0 EXECUTIVE SUMMARY.......................................................................................................1
1.1 INTRODUCTION ..........................................................................................................................1
1.2 ABOUT THE AIRCRAFT FUEL SYSTEM SAFETY PROGRAM (AFSSP)...........................................1
1.3 SCOPE.......................................................................................................................................2
1.4 ABOUT THIS DOCUMENT ...........................................................................................................2
1.5 FINDINGS ..................................................................................................................................2
1.6 ACTIONS AND RECOMMENDATIONS...........................................................................................3
1.7 CONCLUSIONS...........................................................................................................................4
2.0 OVERVIEW.............................................................................................................................5
2.1 INTRODUCTION ..........................................................................................................................5
2.2 SCOPE.......................................................................................................................................5
2.3 INDUSTRY COMMITMENT...........................................................................................................6
2.4 PARTICIPANTS AND ORGANIZATIONS.........................................................................................7
2.4.1 Airworthiness Authorities...................................................................................................9
2.4.2 AFSSP Organization ..........................................................................................................9
2.4.3 Airplane Working Groups ................................................................................................10
2.5 INDUSTRY INSPECTION RESULTS .............................................................................................11
2.5.1 Integrity of Wiring and Bonding Jumpers........................................................................12
2.5.2 Condition of FQIS Wiring and Components ....................................................................12
2.5.3 Condition of Fuel Pumps, Fuel Lines, and Fittings .........................................................12
2.5.4 Electrical Bonding and Grounding of Fuel System Equipment .......................................13
2.5.5 Inspection for Foreign Object Debris (FOD) ..................................................................13
2.5.6 General Tank Condition...................................................................................................13
2.5.7 Geographic and Environmental Conditions ....................................................................13
2.6 ACTIONS AND RECOMMENDATIONS.........................................................................................14
3.0 AIRBUS WORKING GROUP REPORT.............................................................................16
3.1 INTRODUCTION ........................................................................................................................16
3.2 SCOPE.....................................................................................................................................16
3.2.1 Additional Activities .........................................................................................................16
3.3 WORKING GROUP TEAMS ........................................................................................................16
3.3.1 Team Composition............................................................................................................17
3.3.2 Team Activities .................................................................................................................18
3.4 WORKING GROUP APPROACH..................................................................................................18
3.5 INSPECTION CRITERIA..............................................................................................................19
3.6 INSPECTION PROGRAM.............................................................................................................21
3.7 RESULTS .................................................................................................................................26
3.7.1 Bonding Leads..................................................................................................................26
3.7.2 Component Bonding.........................................................................................................26
CONTENTS
Contents (continued)
Page ii Industry AFFSP Report August 4, 2000
3.7.3 FQIS Wiring and Probes..................................................................................................27
3.7.4 General Tank Condition and FOD ..................................................................................27
3.7.5 Tank Structure..................................................................................................................27
3.7.6 Flame Arrestors ...............................................................................................................27
3.8 CONCLUSIONS .........................................................................................................................27
3.8.1 Bonding Leads..................................................................................................................27
3.8.2 Component Bonding Exceedances ...................................................................................28
3.8.3 General Conclusion .........................................................................................................28
4.0 BAE SYSTEMS WORKING GROUP REPORT................................................................29
4.1 INTRODUCTION.......................................................................................................................29
4.2 SCOPE.....................................................................................................................................29
4.3 WORKING GROUP TEAMS........................................................................................................29
4.3.1 Turbofans (BAE SYSTEMS Regional Aircraft—Woodford) ............................................29
4.3.2 Turboprops (BAE SYSTEMS Regional Aircraft—Prestwick) ..........................................30
4.4 WORKING GROUP APPROACH..................................................................................................32
4.4.1 Inspection Types and Criteria..........................................................................................32
4.4.2 Turbofans .........................................................................................................................33
4.4.3 Turboprops......................................................................................................................33
4.5 JET INSPECTION RESULTS ........................................................................................................34
4.5.1 Integrity of Wiring and Bonding Straps ...........................................................................34
4.5.2 Condition of FQIS Wiring and Components....................................................................34
4.5.3 Condition of Fuel Pumps, Fuel Lines, and Fittings.........................................................35
4.5.4 Electrical Bonding and Grounding of Fuel System Equipment .......................................35
4.5.5 Inspection for Foreign Object Debris ..............................................................................35
4.5.6 General Tank Condition...................................................................................................35
4.5.7 Other Items.......................................................................................................................35
4.6 TURBOPROP INSPECTION RESULTS ..........................................................................................35
4.6.1 Integrity of Wiring and Bonding Straps ...........................................................................35
4.6.2 Condition of FQIS Wiring and Components....................................................................36
4.6.3 Condition of Fuel Pumps, Fuel Lines, and Fittings.........................................................36
4.6.4 Electrical Bonding and Grounding of Fuel System Equipment .......................................36
4.6.5 Inspection for Foreign Object Debris ..............................................................................36
4.6.6 General Tank Condition...................................................................................................37
4.6.7 Other Items.......................................................................................................................37
4.7 SUMMARY ...............................................................................................................................37
5.0 BOEING WORKING GROUP REPORT............................................................................39
5.1 INTRODUCTION.......................................................................................................................39
5.2 SCOPE.....................................................................................................................................39
5.3 ADDITIONAL ACTIVITIES .........................................................................................................39
5.4 WORKING GROUP TEAMS........................................................................................................40
5.4.1 Team Composition ...........................................................................................................40
5.4.2 Team Activities .................................................................................................................40
Contents (continued)
August 4, 2000 Industry AFFSP Report Page iii
5.5 WORKING GROUP APPROACH..................................................................................................41
5.5.1 Inspection Program..........................................................................................................41
5.6 RESULTS .................................................................................................................................48
5.6.1 Electrical Bonding............................................................................................................48
5.6.2 Bonding Jumpers..............................................................................................................50
5.6.3 Tubing, Mechanical, and Electrical Component Condition.............................................50
5.6.4 Fuel Quantity Indication System ......................................................................................51
5.6.5 Fuel Leaks ........................................................................................................................52
5.6.6 Access Doors, Panels, and Openings...............................................................................52
5.6.7 Tank Condition.................................................................................................................53
5.6.8 Foreign Object Debris......................................................................................................53
5.7 CONCLUSIONS AND CONTINUING ACTIVITIES ..........................................................................53
6.0 BOMBARDIER WORKING GROUP REPORT................................................................55
6.1 INTRODUCTION ........................................................................................................................55
6.2 SCOPE.....................................................................................................................................55
6.2.1 Additional Activities .........................................................................................................55
6.3 WORKING GROUP TEAMS ........................................................................................................55
6.3.1 Team Composition............................................................................................................56
6.3.2 Team Activities .................................................................................................................56
6.4 WORKING GROUP APPROACH..................................................................................................56
6.4.1 Objectives .........................................................................................................................56
6.4.2 Inspection Program..........................................................................................................56
6.5 CRJ RESULTS ..........................................................................................................................58
6.5.1 Bonding Jumpers..............................................................................................................58
6.5.2 Fuel Quantity Indication System (FQIS) Wiring..............................................................58
6.5.3 Condition of Fuel Pumps, Fuel Lines, and Fittings .........................................................58
6.5.4 Electrical Bonding............................................................................................................59
6.5.5 Foreign Object Debris......................................................................................................59
6.5.6 General Tank Condition...................................................................................................59
6.6 DE HAVILLAND GROUP RESULTS.............................................................................................60
6.6.1 Electrical Wiring and Bonding Jumpers..........................................................................60
6.6.2 FQIS ................................................................................................................................61
6.6.3 Fuel Components, Fuel Lines, and Fittings .....................................................................62
6.6.4 Electrical Bonding and Grounding ..................................................................................62
6.6.5 FOD.................................................................................................................................63
6.6.6 General Fuel Tank Condition...........................................................................................63
6.7 SUMMARY...............................................................................................................................63
7.0 FOKKER WORKING GROUP REPORT...........................................................................65
7.1 SCOPE.....................................................................................................................................65
7.2 WORKING GROUP APPROACH..................................................................................................65
7.3 INSPECTION PROGRAM.............................................................................................................65
7.3.1 Fokker Turboprop Inspection Program ...........................................................................66
Contents (continued)
Page iv Industry AFFSP Report August 4, 2000
7.3.2 Summary of Turboprop Inspection Findings ...................................................................67
7.3.3 Fokker Jet Inspection Program........................................................................................67
7.3.4 Summary of Jet Inspection Findings ................................................................................69
7.4 CONCLUSIONS .........................................................................................................................70
7.4.1 Turboprop ........................................................................................................................70
7.4.2 Jet ....................................................................................................................................70
8.0 LOCKHEED MARTIN WORKING GROUP REPORT...................................................73
8.1 INTRODUCTION.......................................................................................................................73
8.2 SCOPE.....................................................................................................................................73
8.3 WORKING GROUP TEAM..........................................................................................................73
8.4 TEAM COMPOSITION................................................................................................................73
8.5 WORKING GROUP APPROACH..................................................................................................74
8.6 INSPECTION PROGRAM ............................................................................................................74
8.7 INSPECTIONS PERFORMED .......................................................................................................76
8.8 RESULTS.................................................................................................................................77
8.8.1 Fault Current Bonding.....................................................................................................77
8.8.2 Component Wiring ...........................................................................................................77
8.8.3 Static Ground Straps ........................................................................................................77
8.8.4 Couplings .........................................................................................................................78
8.8.5 FOD.................................................................................................................................78
8.8.6 FQIS Wiring .....................................................................................................................78
8.8.7 Vent Flame Arrestors .......................................................................................................78
8.8.8 General Tank Condition...................................................................................................78
8.8.9 Evaluation of Results........................................................................................................78
8.9 ACTION PLAN APPROACH........................................................................................................78
8.10 ACTION STATUS AND CONTINUING EFFORTS.........................................................................79
9.0 CONCLUSIONS .....................................................................................................................81

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Aircraft Fuel System Safety Program Report

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