SFAR 88 Fuel Tank Safety Awareness Training
SFAR 88 Fuel Tank Safety Awareness Training
SFAR 88 Fuel Tank Safety Awareness Training
Lufthansa
Technical Training
SFAR 88 Fuel Tank Safety Awareness Training
Lufthansa
Technical Training
AWARENESS TRAINING SFAR 88 FUEL TANK SAFETY
Page 1
Lufthansa
Technical Training
SFAR 88 Fuel Tank Safety Awareness Training
Lufthansa
Technical Training
AWARENESS TRAINING SFAR 88 FUEL TANK SAFETY
INTRODUCTION
BACKGROUND INFORMATION
General
Since 1959 there have been 17 fuel tank ignition events, resulting in: After arriving at JFK International Airport from Athens, Greece, the plane sat on
542 fatalities the ground for four hours with the air conditioning units operating before
departing for Paris at 8:19 p.m.. The plane exploded 20 minutes later, while
11 hull losses
ascending at 13,760 ft.
3 others with substantial damage.
The central fuel tank, which is capable of holding 13,000 gallons of jet fuel, only
Causes contained 50 gallons at the time it exploded, meaning that it was less than
onehalf percent full. TWA Flight 800 was using Jet A fuel, which is most
3 unknown
commonly used for commercial jets. The central fuel tank is located on the
4 caused by external wing fires underside of the fuselage, directly between the wings.
4 electrostatics
2 lightning
2 pumps or wiring suspected
1 by small bomb
1 maintenance action
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INTRODUCTION
BACKGROUND, CONTINUE
On March 2001, a B737, operated by Thai Airways, was destroyed by an
explosion and fire at Bangkok International Airport, Thailand.
After investigation, the NTSB has determined that the center fuel tank
exploded, shortly after the main fuel tanks were refueled. The cause of the
explosion was the ignition of the flammable fuel/air mixture in the center fuel
tank. The source of the ignition energy for the explosion could not be
determined with certainty, but the most likely source was an explosion
originating at the center tank fuel pumps.
NOTE: The pumps were operating dry (no fuel passing through them) at
the time of the explosion!
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INTRODUCTION
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Figure 2 Thai 737400 Fuel Tank Explosion Lufthansa
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ACCIDENT FINDINGS
ACCIDENT FINDINGS
WHAT CAUSED THE CRASH OF TWA 800?
The National NTSB (Transportation Safety Board) considered TWA 800 the leaking water and lavatory fluids, dust and other materials that build up over
most extensive and encompassing accident investigation ever undertaken by years of service.
the safety board. The NTSB determined that the probable cause of the TWA The presence of sharp metal shavings, which can be attributed to drilling, can
Flight 800 accident was an explosion of the CWT (Center Wing Fuel Tank), strip insulation away from wires. As a result, the core conducting wires become
resulting from ignition of the flammable fuel/air mixture in the tank. The source exposed and enhance the likelihood of a spark. Exposed wires that are coated
of ignition energy for the explosion could not be determined with certainty. with syrup or metallic drill shavings can be dangerous because either
However, of the sources evaluated by the investigation, the most likely was a substance can act as a conductor. Consequently, substances such as these
short circuit outside of the CWT that allowed excessive voltage to enter through could function as a base point for an electric arc, which could ignite the
electrical wiring associated with the fuel quantity indication system. contents of a fuel tank. The NTSB initiated simulations with these conditions to
see if it was possible to create an electrical arc. In one rare case, when bare
The Ignition Source
wires were bundled close to each other, an arc was created.
Upon realizing that the central fuel tank of TWA Flight 800 exploded and that
the explosion was not likely by a bomb, the NTSB focused on finding the Autoignition
source of ignition. However, after scrutinizing all of the recovered wreckage, Another possible source of ignition is from the terminals of the FQIS wires in
which accounts for over 95 % of the plane, they found nothing to support any the central fuel tank on which copper sulfide can build up. This phenomenon
plausible theory of ignition. The investigation focused on examining the has been observed in aging electrical systems, and is a result of the natural
electrical wiring near the central fuel tank, which consists largely of wiring for deterioration of wiring. The buildups can become sources of localized heat.
the FQIS (Fuel Quantity Indicating System) and for control of the fuel pumps. This can cause a threat because of autoignition. If the localized heat source is
Unfortunately, most of this wiring was burned or damaged from the explosion, hot enough, the fuel around it may reach a temperature at which it will
thus hindering an analysis into the role that it could have played in causing the automatically ignite.
explosion. However, this did not leave the NTSB completely in the dark
Another theory of how autoignition could have occurred within the central fuel
concerning ignition sources. Electrical arcing and autoignition are two source
tank of TWA Flight 800 involves the scavenger pump and faulty check valves.
theories that were tested by the NTSB.
The scavenger pump is a possible source of ignition because it resides within
Electrical Arcing the central fuel tank. NTSB officials believe that fuel was being transferred
between tanks when the explosion occurred, suggesting that the scavenger
In search of answers to the question of ignition, the NTSB conducted an
pump in the central fuel tank was operating. If the scavenger pump was
investigation into the state of electrical wiring in operational Boeing 747s and
operating and its check valve was too tight, it may have allowed only fuel, and
similar models from other manufacturers to see if a spark could occur in the
not vapor to pass through it, resulting in a concentration of vapor around the
central fuel tank. The findings from this investigation were discouraging.
check valve of the scavenger pump. The vapors have a lower autoignition
Between May of 1997 and July of 1998, the NTSB examined a number of
temperature than the liquid and the pump is a significant source of energy that
existingjets, of which many were old, reaching ages up to 27 1 /2 years old.
could become hot enough to cause autoignition of fuel vapor.
Findings include sharp metal shavings both on and between wire bundles,
and threequarter inch coatings of lint on wires, what NTSB investigators
describe as syrup: a sticky combination of spilled beverages,
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ACCIDENT FINDINGS
ELECTRICAL ARCING
FUEL AIR
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Figure 3 Accident Findings Lufthansa
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CONSEQUENCES
CONSEQUENCES
AIRCRAFT FUEL SYSTEM SAFETY PROGRAM (AFSSP) The following mission statement was developed by the AFSSP to guide and
focus the efforts of this program:
(Refer to: Aircraft Fuel System Safety Program Report prepared by the
International Aviation Industry, August 4, 2000) Through worldwide industry collaboration, take appropriate action to ensure,
maintain and enhance the safety of fuel systems throughout the life of the
In wake of the tragic TWA Flight 800 accident the collective realization aircraft.
emerged that additional information needed to be gathered regarding the
In the Aircraft Fuel System Safety Program Report prepared and issued by the
condition of airplane fuel tank systems in the world fleet. Consequently, the
International Aviation Industry August 4, 2000 the following statements are
industry in 1997 committed itself to assessing the state of the inservice fleet
given among others under paragraph:
around the world. To accomplish this ambitious goal, the AFSSP (Aircraft Fuel
System Safety Program) was formed. Participants in this voluntary industry 2.6 Actions and Recommendations
program include present and past turbinepowered airliner manufactures, ...
airlines, industry organizations, and airworthiness authorities from around the Based on AFSSP findings, the industry recommends additional training for
world. The following excerpt outlines the goals of the AFSSP: manufacturing and maintenance personnel, and will be reviewing or modifying
The industry is fully committed to enhancing aviation safety and believes that the existing fuel system maintenance practices to:
efforts should be based on facts. The data available at this time indicates that Substantiate the integrity of bonding straps through
the best prevention strategy should focus on improvements - design, operation,
Longterm periodic visual/tactile inspection to verify bond integrity
or maintenance - to enhance fuel tank systems.Therefor the industry plans to
voluntarily undertake either a sampling of hightime aircraft or major fuel tank Enhancements to existing maintenance instructions for bonding jumper
inspection programs to verify maintenance and replacement
the integrity of wiring and grounding straps; Provide periodic inspection criteria for FQIS (Fuel Quantity Indicating
System) wiring and components that are more detailed to better define
the condition of fuel pumps, fuel lines and fittings; and
conditions and items to be inspected during general tank inspections.
the electrical bonding on all equipment.
Provide for the periodic insitu inspection of fuel pumps and associated
The inspection program will not be limited to the Boeing 747; rather, Airbus, wiring, fuel lines, and fittings.
Boeing, Lockheed Martin, and McDonnell Douglas have agreed to jointly sp
The following items are presently part of the periodic heavy maintenance or
onsor a program that covers all of their respective models. In addition, the
structural inspections that are already being conducted, so no change to
airlines represented by the ATA, AEA, and the AAPA have agreed to participate
existing practices is recommended.
in these inspections. The inspection programs findings will be coordinated
through the international industry fuel tank inspection task forces. The industry Inspection for foreign object debris.
proposes that task force participation include the FAA and international au General tank condition.
thorities. Subject to agreement with the authorities, the industry would propose ...
to share findings and plans with the public on a timely basis.
However, findings outside of this inspection program have shown that improper
repair or maintenance of fuel system components can lead to safety issues.
Therefore, the industry believes it is critical to have welldocumented
maintenance procedures and qualified repair stations and personnel
maintaining fuel system components to ensure that design integrity is
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CONSEQUENCES
Official Report:
The probable cause of the TWA Flight 800 accident was an explo-
sion of the center fuel tank (CWT)... neither the energy release mech-
anism nor the location of the ignition inside the CWT could be deter-
mined from the available evidence.
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Figure 4 TWA Flight 800 accident Lufthansa
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REGULATION
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REGULATION
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Engineering Engineering
Modifications of existing systems Reassessment and revision in the
and introduction of new maintenance and overhaul
technologies for the fulfillment of the program and in the documents
SFAR 88 specifications
Employee at aircraft
Awareness of problems in the
working areas of Fuel Vapor and
Wiring
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Specific control specifications are demanded in the aircraft documentation. Possible damages
can be discovered at SFAR 88 relevant components and system components.
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Specific control specifications are demanded in the aircraft documentation. Possible damages
can be discovered at SFAR 88 relevant components and system components.
Example:
Fuel Pumps
Internal components of the stator wiring as a source of spark discharge.
Damages at external cables and corroded connections as a source of spark formation.
Avoidance of fuel pump operation in empty fuel tanks.
2/6
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Specific control specifications are demanded in the aircraft documentation. Possible damages
can be discovered at SFAR 88 relevant components and system components.
Example:
Fuel Pumps
Internal components of the stator wiring as a source of spark discharge.
Damages at external cables and corroded connections as a source of spark formation.
Avoidance of fuel pump operation in empty fuel tanks.
3/6
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Specific control specifications are demanded in the aircraft documentation. Possible damages
can be discovered at SFAR 88 relevant components and system components.
Example:
Fuel Pumps
Internal components of the stator wiring as a source of spark discharge.
Damages at external cables and corroded connections as a source of spark formation.
Avoidance of fuel pump operation in empty fuel tanks.
4/6
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Specific control specifications are demanded in the aircraft documentation. Possible damages
can be discovered at SFAR 88 relevant components and system components.
Example:
Fuel Pumps
Internal components of the stator wiring as a source of spark discharge.
Damages at external cables and corroded connections as a source of spark formation.
Avoidance of fuel pump operation in empty fuel tanks.
Bonding Straps
Failure because of corrosion or improper fastening.
Failure because of mechanical wear and tear due to movements.
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Specific control specifications are demanded in the aircraft documentation. Possible damages
can be discovered at SFAR 88 relevant components and system components.
Example:
Fuel Pumps
Internal components of the stator wiring as a source of spark discharge.
Damages at external cables and corroded connections as a source of spark formation.
Avoidance of fuel pump operation in empty fuel tanks.
Bonding Straps
Failure because of corrosion or improper fastening.
Failure because of mechanical wear and tear due to movements.
6/6
Reassessment and revision in the maintenance and overhaul program and in the
documents
1/2
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CONSEQUENCES FOR MAINTENANCE AND
OVERHAUL
Reassessment and revision in the maintenance and overhaul program and in the
documents
Improved instructions for the topic bonding, as well as regular bonding checks.
Leakage inspection at the fuel center tank and condition of the vapor seals and drip shields.
Execution of bonding check and control of foreign objects before closing fuel tanks.
Leak check after disturbances at a hot air duct nearby fuel tanks.
Measures for avoiding dry running of fuel pumps in accordance with AMM.
AIRBUS BOEING
Trijet Special Compliance Items Report Lufthansa Technik Standard Practices Manual
- MD11 Doc. MDC02K1003 - LHTSPM Approved by FRA WE
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AIRWORTHINESS LIMITATIONS
AIRWORTHINESS LIMITATIONS
INTRODUCTION
This SFAR 88 rule required manufacturers to enhance airplane maintenance The AWLs for each model have been released in the appropriate maintenance
programs to maintain design features that are necessary to prevent an ignition documents for each model. The documents, by model, are listed in the training
source in the fuel tanks. The result of this effort was the incorporation of information attachment. AWLs are expected to be mandated by FAA
several AWLs (Airworthiness Limitations) for Boeing, and FALs (Fuel Airworthiness Directives. Operators should pay particular attention to AWLs
Aiworthiness Limitations) for Airbus into maintenance program documents. during modifications, as SFAR 88 imposes a more significant regulatory
These AWLs are divided into two categories: approval burden on ALI/CDCCL changes than many other maintenance
CDCCL (Critical Design Configuration Control Limitations) for Boeing and program changes. All changes to a CDCCL or ALI or a procedure involving a
Airbus: CDCCL or ALI must be approved by the appropriate regulatory office. The
relevant authority varies by country and model.
These are critical fuel system design features which must be maintained
in order to minimize the creation of a fuel tank ignition source. CDCCLs
are identified in the AMMs, CMMs, and Special Compliance Items
document (for Long Beach models). Some examples of CDCCLs are the
bonding and grounding of fuel system components, and the routing of
fuel system wiring.
ALIs (Airworthiness Limitation Inspections)only for Boeing:
These are repetitive inspections which are required to help ensure that
components which are subject to degradation or damage do not
deteriorate to the point where they may fail and create an ignition source
in the fuel tanks. Some examples of ALIs are verification of fault current
bonds, and inspection of wiring insulation and clamping.
ALIs (Maintenance / Inspection Tasks) only for Airbus:
These tasks must be included in an operators approved maintenance
program/ schedule. The task interval may be quoted in any usage
parameter (FH, FC or Calendar Time) depending on the cause of
potential degradation that, if not detected and addressed, could lead to
an unacceptable risk.
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AIRWORTHINESS LIMITATIONS
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AIRWORTHINESS LIMITATIONS
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AIRWORTHINESS LIMITATIONS
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AIRWORTHINESS LIMITATIONS
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AIRWORTHINESS LIMITATIONS
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FUEL AIRWORTHINESS LIMITATIONS
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FUEL AIRWORTHINESS LIMITATIONS
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Figure 5 Example of Airbus FALs Lufthansa
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FUEL AIRWORTHINESS LIMITATIONS
TASK 284216400801
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Figure 6 Example of A340 Removal/Installation Center Tank Middle-FQI-Probe Lufthansa
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AIRWORTHINESS LIMITATIONS
For the B737, B777, B747 the Maintenance Planning Data are similarly structured. As an exam-
ple a page is shown from the B737 MPD. (B737 External Wires Over the Center Tank Inspection).
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AIRWORTHINESS LIMITATIONS
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AIRWORTHINESS LIMITATIONS
According 28AWL-01
ALI
AMM 280000
D. Airworthiness Limitations Instructions (ALIs)
S 912072
737300/400/500 WARNING: OBEY THE MANUFACTURERERS PROCEDURES
MAINTENANCE MANUAL WHEN YOU DO ANY MAINTENANCE THAT MAY
AFFECT AN ALI. IF YOU DO NOT FOLLOW THE
ASK 281100206281 PROCEDURES, IT CAN IN CREASE THE RISK OF
7. External Wires Over the Center Tank Inspection A FUEL TANK IGNITION SOURCE.
A. General (1) Make sure you follow the procedures for tasks identified as ALIs.
(1) ALI Refer to the task: Airworthiness Limitation
Precautions (AMM 280000/201), for important
information on airworthiness limitation instructions (ALIs). Refer to AMM 280000
According 28AWL-02
CDCCL
EFFECTIVITY 281100
ALL Page 60X
Jan 12/06
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Figure 7 Example of B737 External Wires Over the Center Tank Inspection Lufthansa
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
OXYGEN
A mixture of fuel and Some typical ignition
oxygen can be sources are
extremely
...electrical sparks.
...cable fire.
...hot surfaces.
...friction sparks.
...static discharge.
COMBUSTIBLE IGNITION
...explosive
MEDIUM SOURCE
In aircraft maintenance and overhaul all areas of the fuel tanks have to be inspected for present
damages and their possible causes.
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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Figure 8 Fuel Tank Ignition Source Consideration Lufthansa
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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Figure 9 Fuel Tank Ignition Source Consideration, Cont. Lufthansa
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
INDIRECT DAMAGE
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
INDIRECT DAMAGE
CHEMICAL CONTAMINATION
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
INDIRECT DAMAGE
CHEMICAL CONTAMINATION
HEAT
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
INDIRECT DAMAGE
CHEMICAL CONTAMINATION
HEAT
INSTALLATION 4/4
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Figure 10 Causes of Wiring Degradation Lufthansa
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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FACTORS FOR AN EXPLOSION OF THE
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IMPROPER
Power cables can become damaged
when riding on structure.
PROPER
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Figure 11 Causes of Wiring Degradation, Cont. Lufthansa
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
IMPROPER
Wire bundles that cross should be
secured together to avoid chafing
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PROPER
Figure 12 Wires Riding on Other Wires Lufthansa
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
IMPROPER
If the grommet is too short, wire bundle
chafing can occur.
PROPER
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Figure 13 Wires Riding on Lightening Hole Lufthansa
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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FACTORS FOR AN EXPLOSION OF THE
FUEL TANK
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Figure 14 Wires in the bundle are not tied properly Lufthansa
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FLAMMABILITY REDUCTION SYSTEM
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FLAMMABILITY REDUCTION SYSTEM
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SUMMARY
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SUMMARY
Measures to mak e sure the airworthiness of the aircraft with support of Product or System Engineering by:
Measures to make sure the airworthinessof the aircraft with su pp
or ot f oPr uc
d t or S stem
y En ineeri
g n g by:
good workmanship,design modifications, operational procedures , interim actions
good workmanship , design modifications operational
, procedures interim
, action s
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Figure 16 Control Sequence at AWL Relevant Components Lufthansa
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TABLE OF CONTENTS
SFAR 88 FUEL TANK SAFETY AWARENESS TRAINING
AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENHANCED AIRWORTHINESS PROGRAM, EASA DECISION
NO 2007/002/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION OF THE SFAR 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BACKGROUND INFORMATION . . . . . . . . . . . . . . . . . . . . 2
BACKGROUND, CONTINUE . . . . . . . . . . . . . . . . . . . . . . . 4
ACCIDENT FINDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHAT CAUSED THE CRASH OF TWA 800? . . . . . . . . . 6
CONSEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AIRCRAFT FUEL SYSTEM SAFETY PROGRAM (AFSSP) . . . . . .
8
AIRWORTHINESS DIRECTIVES ISSUED . . . . . . . . . . . 10
CONSEQUENCES FOR MAINTENANCE AND OVERHAUL . . . . . . 12
AIRWORTHINESS LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL AIRWORTHINESS LIMITATIONS EXAMPLE . . . . . . . . . . . . . . 18
EXAMPLE OF AIRBUS FUEL AIRWORTHINESS LIMITATIONS .
18
EXAMPLE OF BOEING AIRWORTHINESS LIMITATIONS . . . . . .
21
REASONS FOR A FUEL TANK EXPLOSION . . . . . . . . . . . . . . . . . . . 24
RECOMMENDATIONS TO MINIMIZE IGNITION SOURCES . . . .
26
CAUSES OF WIRING DEGRADATION . . . . . . . . . . . . . . 30
EXAMPLES OF WIRING PROBLEMS . . . . . . . . . . . . . . . 32
WIRING ROUTING, CONT. . . . . . . . . . . . . . . . . . . . . . . . . 36
FLAMMABILITY REDUCTION SYSTEM (FRS) . . . . . . . . . . . . . . . . . . 38
AVOIDANCE OF THE EXPLOSION HAZARD BY NITROGEN
INERTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SUMMARY - FUEL TANK SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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TABLE OF FIGURES
Figure 1 Background for the Introduction of the SFAR 88 . . . . . . . . . . . . 3
Figure 2 Thai 737400 Fuel Tank Explosion . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3 Accident Findings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 4 TWA Flight 800 accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5 Example of Airbus FALs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 6 Example of A340 Removal/Installation Center Tank
Middle-FQI-Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 7 Example of B737 External Wires Over the Center Tank Inspection .
23
Figure 8 Fuel Tank Ignition Source Consideration . . . . . . . . . . . . . . . . . . . 27
Figure 9 Fuel Tank Ignition Source Consideration, Cont. . . . . . . . . . . . . . 29
Figure 10 Causes of Wiring Degradation . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 11 Causes of Wiring Degradation, Cont. . . . . . . . . . . . . . . . . . . . . . 33
Figure 12 Wires Riding on Other Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 13 Wires Riding on Lightening Hole . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 14 Wires in the bundle are not tied properly . . . . . . . . . . . . . . . . . . 37
Figure 15 Flammability Reduction System . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 16 Control Sequence at AWL Relevant Components . . . . . . . . 41
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