05 ATA28&47 Fuel&Inerting - 2012

Aviation Systems Design
Frederic ABADIE
frederic.abadie@gmail.com
Frederic ABADIE
Principle & Architecture

Engine fuel feed System
Refuel / Defuel System

Jettison System Components : Fuel pumps & sensors Cockpit Display
2012-2013


2012-2013
Fuel System ensures :

Fuel feed to engines and APU among all flight phases
Fuel tanks filling and emptying Computation of fuel quantity (volume & weight) in each tank Cooling of Aircraft elements : Hydraulic circuits, Engine Electrical
Generators... Monitoring of the system and reporting to the pilot Participation to Aircraft weight balancing (A/C equipped with trim tanks)
Fuel quantity is given in kilograms or pounds (1 lb = 0.453 kg)
Fuel density ~0.785 kg/l Jet A/A1 is the most common fuel used in aviation industry
2012-2013
Example of architecture 3 tanks
Fuel feed gallery
2012-2013


2012-2013
Engine fuel feed
2012-2013
Refuel / Defuel system controls :

Automatic or Manual refuel
Manual defuel Manual ground transfer between the tanks
Fuel Control Computer manages the refuel /
defuel / ground transfer and monitors fuel quantity and quality
An external Fuel Control Panel allows to
launch manual and auto refuel / defuel and ground transfer

2012-2013 Aviation Systems Design 9
Aircraft Refuelling
Refuel couplings are connected to the refuel gallery through an isolation valve
Defuel / Jettison valves are used for pressure defuel or ground transfer by connecting Engine feed gallery to Refuel gallery
2012-2013 Aviation Systems Design
Refuel gallery is connected to each tank through inlet valves
10
To jettison = to throw away (Collins dictionary)

In case of emergency landing, Jettison system allows to throw away fuel in flight to avoid landing above MLW (Max Landing Weight)
Jettison :

is limited to ~1 ton per minute and per valve
is Manually initiated from cockpit P/B

is Manually or automatically stopped by Fuel Control Computer when : Target weight is reached Centre tank is dry
2012-2013
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2012-2013
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2012-2013
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Fuel Pumps
At least 2 fuel pumps are installed in each tank (for redundancy). They are
constantly fed with fuel to avoid air ingestion.

Fuel pumps are the only equipment within the tanks
requiring high electrical power. To prevent ignition :

Pumps are installed in self-contained explosive canisters
All electrical harnesses are EXTERNAL to fuel tanks
Override pumps are usually installed in centre tank
to force centre tank to be emptied first for flight performance and ETOPS / LROPS(*) considerations
Engines can be fed by gravity fuel feed from outer tanks when pumps fail Fuel pumps allow to re-circulate fuel to avoid freezing and to reach
homogeneous fuel quality in all tanks

(*) Extended range
2012-2013
Twin-engine Operation Performance Standard Long Range Operational Performance Standard

14
Fuel sensors
Fuel sensors are powered at low voltage (< 5V) and installed as far as possible from elements connected to electrical ground
Capacitive fuel gauges
Used for fuel level indication Up to 150 gauges per Aircraft
R R: Radius of gauge cylinders r: permittivity of Air 0 : permittivity of Fuel
Densitometers
Allow to calculate the weight corresponding to the measured volume
Vibrating device : resonance frequency varies with fuel density
Temperature sensors
Standard thermal resistance Temperature = f (resistance)


2012-2013
16
Example of ECAM Fuel page

Valve normally open Valve normally closed Pump normally in Stand by Pump normally running
4 Wing Tanks 1 Centre Tank
1 Trim Tank
2012-2013
17
Frederic ABADIE
Why inerting ?
Regulation
System Architecture
Components :
Air Separation Module
Ozone converter
Inerting Control Computer
2012-2013
19
Why inerting ?
Regulation
System Architecture
Components :
Ozone converter
2012-2013
20
Fuel tank explosion is possible when 3 elements get together :

Fuel vapour
Oxygen Ignition source
Jet A flammability
Fuel
Fire
O2
Historical approach (starting 60s):

To reduce fuel flammability, Airworthiness Authorities used to request to prevent the presence of possible ignition sources in fuel tanks
But accidents have shown that empty centre tanks are exposed to explosion risk
5 accidents caused by fuel vapour explosion

2 on ground :
2 Lightning strikes : B707 1963 B747 1976
B737-300 1990
B737-400 2001
1 in flight
2012-2013 Aviation Systems Design
B747-100 1996
22
Why inerting ?
Regulation
System Architecture
Components :
Ozone converter
2012-2013
23
SFAR(*)88 finalised Dec. 2002, requires to :

Conduct a revalidation of the fuel tank system designs on the existing
fleet of transport category airplanes carrying 30 or more passengers or a payload of 7,500 lbs. or more
Develop all design changes required to demonstrate they meet the new
ignition prevention requirements

New requirement : Fuel tank
O2 concentration : < 12% on ground (< 15,5% at 40 000 ft)
Ullage = air / fuel vapour
Fuel
Fuel
Fire
Heat sources
(*) Special
O2
Federal Aviation Regulation

Aviation Systems Design 24
2012-2013
Why inerting ?
Regulation
System Architecture
Components :
Ozone converter
2012-2013
25
FTIS : Fuel Tank Inerting System IGGS : Inert Gas Generation System OBIGGS : On Board IGGS
3 2 1
5 4 6
OZONE converter to protects ASMs
2012-2013
26
Why inerting ?
Regulation
System Architecture
Components :
Ozone converter
2012-2013
27

Air Separation Module is the main element with Inerting System
ASMs separate air into Nitrogen Enriched Stream
(NEA) & Oxygen Enriched Stream (OEA)

NEA is directed to fuel tanks via 1 or several injection points OEA is directed overboard via dedicated port
Incoming air shall be temperature controlled :

- To optimize ASM performance (60C +/- 10%) - To ensure ASM cartridges life saving (< 90C)
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Ozone converter
Protects ASMs from OZONE which degrades ASM life
Ozone converter core incorporates precious metal (manganese oxide) allowing catalyst reduction of O3 into O2 Effectiveness of catalyst metal degrades over time, due to bleed air contaminants Typical efficiency :
96% @200C (new) 85% after 600 Flight Hours
Density of ozone : 2.14 kg/m3 Density of air : 1.29 kg/m3 Ozone half-life : 3 months @ -50C 3 days @+20C
Ozone converters are also used to reduce O3 level in Cabin Air Ozone concentration above 5 ppm presents risks for human health
2012-2013
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Commands inerting function depending on flight phase
Source : Flight-testing of the FAA Onboard Inert Gas Generation System on an AIRBUS A320 (June 2004)
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Drives Inerting systems valves to regulate :
Incoming air flow temperature (~ 60C) through heat exchanger Incoming air flow pressure and flow through Bleed inlet valve
Switches between Low / Mid / High flow of NEA towards fuel tanks by
driving Dual Flow Shut Off Valve

Allows to isolate the IGGS from the fuel tank Provides System monitoring information to the crew Report System status through BITE function
2012-2013
31
Questions ?

05 ATA28&47 Fuel&Inerting - 2012

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Aviation Systems Design

Aviation Systems Design

Principle & Architecture

Refuel / Defuel System

Aviation Systems Design

Principle & Architecture

Refuel / Defuel System

Aviation Systems Design

Fuel System ensures :

Aviation Systems Design

Example of architecture 3 tanks

Fuel feed gallery

Aviation Systems Design

Principle & Architecture

Refuel / Defuel System

Aviation Systems Design

Engine fuel feed

Aviation Systems Design

Refuel / Defuel system controls :

Fuel Control Computer manages the refuel /

defuel / ground transfer and monitors fuel quantity and quality

An external Fuel Control Panel allows to

launch manual and auto refuel / defuel and ground transfer

Refuel gallery is connected to each tank through inlet valves

To jettison = to throw away (Collins dictionary)

is limited to ~1 ton per minute and per valve

is Manually initiated from cockpit P/B

Aviation Systems Design

Aviation Systems Design

Principle & Architecture

Refuel / Defuel System

Aviation Systems Design

constantly fed with fuel to avoid air ingestion.

requiring high electrical power. To prevent ignition :

Override pumps are usually installed in centre tank

homogeneous fuel quality in all tanks

Aviation Systems Design

Twin-engine Operation Performance Standard Long Range Operational Performance Standard

Vibrating device : resonance frequency varies with fuel density

Principle & Architecture

Refuel / Defuel System

Aviation Systems Design

Example of ECAM Fuel page

4 Wing Tanks 1 Centre Tank

Aviation Systems Design

Aviation Systems Design

Aviation Systems Design

Aviation Systems Design

Fuel tank explosion is possible when 3 elements get together :

Historical approach (starting 60s):

5 accidents caused by fuel vapour explosion

2 Lightning strikes : B707 1963 B747 1976

Aviation Systems Design

SFAR(*)88 finalised Dec. 2002, requires to :

ignition prevention requirements

O2 concentration : < 12% on ground (< 15,5% at 40 000 ft)

Ullage = air / fuel vapour

Federal Aviation Regulation

Aviation Systems Design

OZONE converter to protects ASMs

Aviation Systems Design

Aviation Systems Design

Air Separation Module