Fuel Tank Safety Training: Risks, Regulations, and Best Practices

Course Overview

This course provides comprehensive knowledge on fuel tank safety, including the regulatory framework, ignition risk assessment, flammability reduction, and best maintenance practices. It explores lessons learned from major accidents, the evolution of global safety standards, and the integration of human factors and SMS in fuel system safety management.

Learning Objectives

• Understand the purpose, significance, and background of fuel tank safety.
• Interpret key FAA, EASA, and ICAO fuel system safety regulations.
• Identify ignition sources and flammability risks within aircraft fuel systems.
• Apply mitigation measures including inerting, grounding, and inspection techniques.
• Follow best practices for maintenance, cleaning, and fuel tank entry procedures.
• Recognize human factors and SMS integration in fuel safety programs.

Course Modules

Module 1: Introduction to Fuel Tank Safety

• 1.1 Purpose and Importance of Fuel Tank Safety
• 1.2 Historical Background
• 1.3 Review of Major Incidents (e.g., TWA 800)
• 1.4 Impact of Fuel Tank Explosions on Regulatory Changes

Module 2: Regulatory Framework

• 2.1 FAA Regulations and Guidance:
  • 14 CFR Part 25.981 — Fuel Tank Explosion Prevention
  • SFAR 88 (Special Federal Aviation Regulation No. 88)
  • AC 25.981-1C and AC 120-97A
• 2.2 Historical JAA Framework — TGL No. 47 and the Foundation of EASA AMC 20-22
• 2.3 EASA Regulations and Guidance:
  • CS 25.981 (Certification Specification for Large Aeroplanes)
  • AMC 20-22 (Airworthiness and Maintenance Considerations for Fuel Tank Systems)
  • EASA Part-M, Part-66, and Part-145 Requirements
• 2.4 ICAO Standards:
  • Annex 6 – Operation of Aircraft
  • Annex 8 – Airworthiness of Aircraft
• 2.5 Results of FAA’s SFAR 88 and JAA’s INT POL 25/12
• 2.6 Airworthiness Limitations:
  • CDCCL – Critical Design Configuration Control Limitations
  • ALI – Airworthiness Limitation Items

Module 3: Fire and Explosion Risks in Fuel Tanks

• 3.1 Understanding the Fire Triangle in Fuel Systems
• 3.2 Fuel Vapor Characteristics and Flammability Limits
• 3.3 Ignition Source Hazards:
  • Electrical Faults
  • Static Discharge
  • Overheating Components
  • Maintenance-Induced Risks

Module 4: Sources of Fire Ignition and Mitigation Measures

• 4.1 Fuel System Components and Ignition Hazards:
  • Fuel Pumps
  • Fuel Quantity Indication System (FQIS)
  • Fuel Quantity Probes
  • Bonding and Grounding Systems
  • Pneumatic and Hydraulic Systems
  • Vent Lines, Wiring Harnesses, and Related Systems
• 4.2 Electrical Wiring Interconnection System (EWIS) in Relation to Fuel System Safety:
  • Inspection Techniques for Wiring and Connectors
  • Common EWIS Degradation Mechanisms (Heat, Vibration, Contamination)

Module 5: Flammability Reduction and Inerting Systems

• 5.1 Principles of Flammability Reduction
• 5.2 Fuel Tank Inerting Systems (OBIGGS, NEA Systems)
• 5.3 Maintenance Considerations for Inerting Systems
• 5.4 Monitoring and Fault Reporting

Module 6: Fuel Tank Maintenance Best Practices

• 6.1 Maintenance Human Factors — Awareness and Precautions
• 6.2 Inspection Techniques:
  • Visual, Electrical, and Continuity Inspections
  • Bonding and Grounding Checks
• 6.3 Cleaning, Sealing, and Corrosion Prevention
• 6.4 Fuel Tank Entry Procedures and Safety Precautions
• 6.5 Control of Tools, Equipment, and Materials Inside Tanks
• 6.6 Post-Maintenance System Testing and Verification

Module 7: Safety Management and Human Factors

• 7.1 Integration with the Safety Management System (SMS)
• 7.2 Human Performance and Error Prevention
• 7.3 Communication and Safety Reporting Culture
• 7.4 Lessons Learned from Fuel Tank Safety Incidents

Module 8: Case Studies

• 8.1 Case Study: Thai Airways B737-400 Fuel Tank Explosion (March 2001)
• 8.2 Case Study: Philippine Airlines Flight 143 Center Tank Explosion (1990)

Who Should Attend

• Certifying staff (EASA Part-66 B1/B2 license holders)
• Aircraft maintenance engineers and technicians
• CAMO and Part-145 maintenance organisation personnel
• Quality, safety, and compliance managers
• Training and technical instructors
• Aircraft maintenance planners and supervisors
• Regulatory authority inspectors or auditors
• Anyone involved in aircraft fuel system inspection, maintenance, or management

Final Assessment & Certification

Upon completion, participants will take a final assessment to demonstrate their understanding. A Certificate of Completion will be awarded to those who meet the passing criteria.

• Mode: Online
• Course Duration: 100 Minutes
• Validity: 365 Days
• We carefully evaluate the candidates taking up this course. Email us at info@academyaviationonline.com and share your interest in taking up this course.