Fuel system test requirement post A380 RIB repair

Fuel Test Requirement-Post RIB boom repair

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

November 2012

Fuel system test requirement post A380 RIB repair

November 2012

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.

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Fuel system test requirement post A380 RIB repair

November 2012

Agenda:

1. Background
2. Fuel pressure tests
3. Air Pressure tests
4. Overflow test
5. Visual inspection
6. Summary
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Fuel system test requirement post A380 RIB repair

November 2012

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

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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Fuel system test requirement post A380 RIB repair

November 2012

2.Fuel Pressure tests (1/2)

-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

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Fuel system test requirement post A380 RIB repair

November 2012

2. Fuel pressure tests (2/2)

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

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FEED TANK 1(4)

FUEL/OIL Heat
Exchanger

Fuel system test requirement post A380 RIB repair

November 2012

3. Air pressure tests

-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 (28-12-00730-806-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

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Fuel system test requirement post A380 RIB repair

Vent system removal :

To be removed
Not to be removed
RIB repair

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November 2012

Fuel system test requirement post A380 RIB repair

November 2012

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)

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Fuel system test requirement post A380 RIB repair

November 2012

3.Air Pressure and free flow test-RIB 3

-Feet removal/installation kinematic:

Blanking
caps-RIB 2

Air pressure Rig

test RIB6

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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Fuel system test requirement post A380 RIB repair

November 2012

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

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 overfillingconfirm 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

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Fuel system test requirement post A380 RIB repair

November 2012

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

-Overfilling of Outer
tank

-Fuel pressure monitored at water

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

-By transfer gallery

-Fuel from opposite
wing

-Once Outer tank is full:

nk
Ta
d
e
Fe

-Fuel pressure increase.

-Fuel overflow from Outer
to Surge through vent
system.

te
Ou
k
an
tT
n
Ve

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

k
an
T
r

ank
eT
g
r
Su

1(4

Fuel system test requirement post A380 RIB repair

November 2012

5.Visual inspection-From Vent to Surge 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

-Source of light in
the surge tank by a
torch

No specific tool required

Procedure detailed in the SBs

-Unbroken circular beam

of light should be
observed from vent tank.

e
Fe

te
Ou
k
an
tT
n
Ve

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k
an
T
r

ank
eT
g
r
Su

nk
Ta

1(4

Fuel system test requirement post A380 RIB repair

November 2012

SB/FUEL TEST-Summary

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