Fuel Test Requirement Post SB RBR

Fuel Test Requirement-Post RIB boom repair

Presented by: Fabien TURPAUD / Fuel System Engineer Customer Services Engineering

November 2012Fuel system test requirement post A380 RIB repair

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Preface

This presentation provide operators with an overview of the fuel test requirement for RIB boom repair. Presentation is issued prior to SB 57-8062/70 issuance and

therefore may be subject to slight changes.

It is not intended to provide a complete guide or instruction, moreover a quick and simple familiarisation of the fuel system tests.

Detailed test instruction are available in the AMM tasks referenced in this presentation or will be detailed in SB 57-8062/70.

November 2012

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Fuel system test requirement post A380 RIB repair


Agenda:

1. Background

2. Fuel pressure tests

3. Air Pressure tests

4. Overflow test

5. Visual inspection

6. Summary

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1.BACKGROUND:

• Fuel System removal for RBR access:

1.Refuel/Transfer galleries→ All pipes in the RIB repair area.

2.Feed system → All pipes in the RIB repair area.

3.Venting system → Pipes removal minimised as follow, to optimised fuel test:

• Fuel test requirement post Fuel System re-installation:

1.Refuel/transfer galleries → Fuel pressure test (AMM)

2.Feed system →Fuel pressure test (AMM )

3.Venting system tests required to confirm:

• Sealing assembly → By Air pressure test (AMM and SBs).

• No blockage within vent→ Overflow test (SBs).

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Mid Tank between RIB 17-18Outer Tank between RIB 36-40Feed tank 2(3) between RIB 2-7



2.Fuel Pressure tests (1/2)

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-AIM: Confirm correct sealing of assembly, by pressurising line with fuel.

-To be performed on:

-FEED LINE

-TRANSFER LINE

-HEAT EXCHANGER PIPE

FUEL Pressure Test on FEED LINE:

-No specific tool required →Line pressurised by Main Fuel Pumps

- Fuel quantity required at least: 1000kg

-Procedure defined in AMM TASK 28-21-00-790-801-A Leak Test of the Engine Feed Galleries After Maintenance

-Post pressure test: tank entry must be done to inspect any mark of leak or seepage.

FUEL Pressure Test on TRANSFER LINE:

-No specific tool required →Line pressurised by Transfer Fuel Pumps or Refuel facilities

- Fuel quantity required : 3700kg

-TASK 28-25-00-790-801-A Leak Test of the Refuel/Transfer Galleries After Maintenance Using Fuel Tanker/Pump Unit



2. Fuel pressure tests (2/2)

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FUEL Pressure Test of the Heat Exchanger Pipes :

-Specific tool required, provided by Airbus Kit P/N:98L28004034000

-Line pressurised by Main Fuel Pumps

- Fuel quantity required: 3000 kg

-Procedure detailed in AMM TASK 28-29-00-790-801-A Leak Test of the Heat Exchanger Pipes

-Post pressure test: tank entry must be done to removed Blanking CAP.

Line to be Tested

Diffuser replaced by Blanking Cap for

Test.

FUEL FEED LINE

FUEL/OIL Heat Exchanger

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FEED TANK 1(4)



3. Air pressure tests

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-AIM: Confirm correct sealing assembly, by pressurising line with AIR.

-To be performed on Vent and Drainage Pipes.

- Specific Airbus Kit will be provided (P/N:98L28004034000) with:

-Blanking Cap

-Bleed Adaptors

-Inflation Adaptors

-Following Air Pressure test procedures should be performed post RBR:

-TASK 28-12-00-730-802-A Pressure Test of the Outer-Tank Vent-Pipe System

-TASK 28-12-00-730-808-A Pressure Test of the Surge-Tank Vent-Pipe System

-TASK 28-21-00-790-802-A (Leak Test of the Air Release Pipes)

-TASK 28-12-00-730-807-A Pressure Test of the Vent Tank Drain-Pipe in the Outer Tank

-TASK 28-12-00-730-806-A Pressure Test of the Surge Tank Drain-Pipe in the Feed Tank 1(4), Alternate procedure without tool by fuel transfer available in AMM task (28-12-00- 730-806-A01), recommended by airbus.

-SB57-8065 Subtask 578065-780-401-001 - Pressure test of vent feed tank 2(3) between RIB 2 and 6 defined for RBR will be detailed in SB 57-8065



Vent system removal :

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November 2012

To be removed

Not to be removedRIB repair



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RIB 14 and 24 vent pipes specificity.

-Access at RIB 24:

-Access for repair difficult.

-Appropriate standard tools to be used(offsets, short drills & long drills)


-Access at RIB 14

-Access for repair difficult.

-Appropriate standard tools to be used(offsets, short drills & long drills)


3.Air Pressure and free flow test-RIB 3

• Vent gallery from FT3 connected to MID, INR and Surge tanks

• Alternate test defined to avoid extra maintenance in other tanks (MID, INR and Surge)

• Test Procedure defined in SB57-8065:• Free flow test → Confirm no partial or complete blockage in the line.

• Air pressure test → Confirm sealing assembly.

• Tool provided in kit P/N:98L28004034000

• No overflow required from this tank.

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Air pressure Rig test –RIB6

Blanking caps-RIB 2

-Feet removal/installation kinematic:



4.Overflow test from outer tank (1/2)

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Background:

Due to removal of Vent pipe from Outer tanks:

•Confirmation of no partial/complete blockage of the Vent system must be performed:

→Failure mode note detected by Air pressure test

Procedure:

Full refuel of the Outer tank

Overfilling of the outer tank by transfer pumps, from opposite wing

Fuel pressure monitored during refuel and overfilling→confirm any partial/complete blockage in the line.

•Specific tool kit provided (P/N: 98L28004034)

•Fuel Distribution required:

Opposite Inner tank:4900 Kgs

Opposite Mid: 3000 Kgs

Opposite Outer Tank 800: Kgs

Trim Tank: 2500 Kgs

Outer Tank (Tested Tank): 8100 Kgs



4.Over Flow test from outer tank (2/2)

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Vent Tank

Outer Tank Surge Tank

Feed Tank 1(4)

-Overfilling of Outer tank

-By transfer gallery

-Fuel from opposite wing

-Once Outer tank is full:

-Fuel pressure increase.

-Fuel overflow from Outer to Surge through vent system.

-Fuel pressure monitored at water drain valve-Tool Kit P/N: 97L28001013000-Aim: confirm any partial or complete blockage of the vent line.



5.Visual inspection-From Vent to Surge tank:

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Vent Tank

Outer Tank Surge Tank

Feed Tank 1(4)

-Source of light in the surge tank by a torch

-Unbroken circular beam of light should be observed from vent tank.

Due to removal of Vent pipe from Outer tanks:

•Confirmation of no partial/complete blockage of the Vent must be performed:

→Failure mode not detected by Air pressure test

No specific tool required

Procedure detailed in the SBs



SB/FUEL TEST-Summary

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November 2012



Month 200X Use Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

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Fuel Test Requirement Post SB RBR