Engineering Aerospace: Aircraft Fuel Systems

Minimal functional requirement of fuel systems is to supply fuel to the engine

in sufficient quantity and quality and at a certain pressure. The system
contains of two sub-systems; the fuselage fuel system and the engine fuel
system. This web page deals with the former sub-system.

The construction of the fuel tank system largely depends on the task of
getting the fuel from the tank to the tank's exit, and from the tank's exit to
the engine. The location of the tanks is usually determined by the platform's
structure, available space and impact on CG (centre of gravity) location. In
some aircraft, external tanks, belly tanks or tip tanks may be fitted. When
additional fuel is needed, for example, for an extended range, ferry tanks are
employed.

Belly Tank [http://www.airglas.com/belly_tank/index.html]

External Tank [http://aeroweb.brooklyn.cuny.edu/specs/mcdodoug/fa-

18b.htm]

Tip Tank [http://www.utility-aircraft.com/gallery/cessna C310/delivery

C310Q.htm]

Ferry Tank

Components of fuel system

Low pressure feed system

Plumbing

Plumbing is the name given to the fuel supply lines. They are depicted as
solid in the illustration but in real life obviously this is not true.

Lines are generally made from metallic tubing, not pipes.

Routing must be placed on the opposite side of the aircraft from the oxygen
supply and below any electrical wiring.

The flow of fuel inside the fuel lines may produce static electricity. The lines
are therefore electrically connected to prevent any electrical charge
accumulation.

Fuel tank

This is the fuel storage component. It must be large enough to carry fuel for
the whole mission.

Fuel tanks must have means of dumping fuel in cases of emergency.

They must be vented so that used fuel may be replaced by air or inert gases.
If there is insufficient flow of air into the tank, it may collapse (due to loading
caused by high performance or steep descend from altitude to sea level). For
integral wing tanks, the pressure difference may cause structural damage
and component failure.

Fuel tanks may have a sump which collects water and solid particles in fuel.

Level indicator

As the name suggests, this component provides the flight crew with the
current measurement of fuel content.

Fuel measurement are difficult to measure as they depend on fuel tank shape
and aircraft attitude.
Pumps

The pumps may be mounted externally or immersed in the fuel.

It is important that the pumps are free of fuel vapour intrusion as they supply
fuel to the engine. To avoid this, air separators are installed at the pump
inlets.

Pressure switch

The switch gives no indicator of the pressure value but rather reacts to the
presence of pressure which is above the pre-set lower limit of the switch.

Relying solely on pump power indication is insufficient because even though

power switch may be on, the pump may not be working due to seized rotor or
blocked inlet. The pressure switch accounts for this.

It gives the flight crew an indication of which pumps are operating since not
all pumps are switched on during operation (during take-off and aerobatics,
both pumps are on).

Non Return Valves (NRV's)

Since during operation only one pump may be working, the NRV ensures that
fuel pumped from the operating pump is not returned to the fuel tank via
inoperative pump.

Pump by-pass valve

This valve allows the fuel from other tanks to enter the indicated tank.

If incorporated with a cross feed valve, it becomes a three way valve.

Tank isolation valve

This valve isolates the tank from the fuel system. This is usually done in
cases of emergency or if a fuel leak develops in the tank, thus draining the
remaining aircraft fuel.

Under normal operating conditions, this valve is open.

Cross feed valve

Requirements state that the engine may only be supplied with fuel from one
tank at a time. The cross feed valve allows for this. It supplies fuel from other
tanks.

This valve is usually closed under normal operating conditions.

Low pressure valve

This valve is fitted after all tanks have had access to the fuel line.

It allows maintenance on any part of the fuel circuit in the fuselage that is not
connected to the tank fuel distribution circuit.

Power drain valve

This valve allows quick discharge of fuel from the system for maintenance or
emergency purposes.

Power drain valve must be closed before engine start up.

High pressure feed system

Backing pump

This is not an essential component, however, in case the engine requires a

fuel pressure higher than that produced by tank pumps, this pump is able to
do so.

It is required that the engine must still operate without the use of this pump.

Fuel Cool Oil Cool (FCOC)

The volatility (ability of evaporate) of fuel may be increased by heating it.

This is particularly important if fuel is supplied from wing tanks where it has
been exposed to low temperature soak at altitude.

The hot oil from engine heats up the cool fuel and in the process cools itself
off, thus reducing the number of oil cooling components in the platform.

Fuel heater

If additional fuel heating is required, the fuel heater is able to do this by the
use of high pressure compressor gas.

Fuel filter

As the name suggests, this component filters out unwanted particles

contained in the fuel.

The filter may be configured to trap water, in which case, it may become
blocked up due to ice formation.

To avoid clogging when contaminants and/or ice are trapped, a bypass valve
is installed to get around a blocked filter.

Regular inspection is essential unless the filter is equipped with an electrical

signalling device which indicates blockage.

Generally, change over from fuselage to engine occurs between these two
components.

Flow meter

Quantity of fuel supplied to the engine is an important piece of information

for management of flight fuel use.

If installed as it is depicted in the above illustration, it doesn't account for the

fuel bypassing the engine and returning to tanks.

To give a correct fuel flow to engine indication, it can be installed after the
fuel control unit (FCU) where any fuel flowing must go to the engine.

Pressure transmitter
This transmitter measures the pressure of the fuel entering the engine.

If there is a problem during the mission, the flight crew can eliminate the fuel
pressure as a cause of this problem by reading the value off the pressure
transmitter.

Pressure switch

This switch monitors the pressure of fuel entering the engine. If a low
pressure is sensed, the switch automatically alerts the crew and activates
master caution warning.

High Pressure pump (HP pump)

This gear pump supplies the engine with fuel and is driven through an
accessory gearbox mounted to the engine.

It is capable of producing pressures of up to 5.5 MPa.