Rajan Wilcox
Aircraft fuel tanks are an essential component of an aircraft's fuel system, storing and delivering clean fuel to the engine at the correct pressure and flow rate. They are designed to withstand rigorous conditions during flight, such as vibration, aerodynamic forces, and even potential lightning strikes, without leaking or deforming. These tanks are typically made from materials like aluminum alloy or stainless steel and are constructed to prevent leaks through riveting and welding. There are several types of aircraft fuel tanks, including integral, rigid removable, and bladder tanks, each with its own advantages and suitability for different aircraft models. The placement of these tanks within the aircraft, such as in the wings or fuselage, plays a crucial role in maintaining the aircraft's structural integrity and balancing weight distribution.
| Characteristics | Values |
|---|---|
| Types | Integral, rigid removable, bladder, wet wing, drop, external |
| Construction | Integral tanks are constructed within sealed areas inside the aircraft structure. Rigid tanks are built separately and installed in the wings or fuselage. Bladder tanks are made of reinforced flexible materials like synthetic rubber. |
| Placement | Most large aircraft store fuel in the wings. Some aircraft also have tanks in the center body or fuselage. Fuel tanks are placed in the wings to reduce stress and wing bending loads, and to prevent weight from being off-center from the plane's center of gravity. |
| Maintenance | Fuel vapours must be removed before welding to avoid an explosion. Tanks must be permanently sealed to prevent external contamination. Rigid tanks undergo pressure testing to ensure they don't leak or collapse. |
| Safety | Fuel tank explosions have been implicated in aviation disasters. The risk of explosion can be reduced with a fuel tank inerting system or fire-fighting foam. |
| Refueling | During refueling, up to 800 kg of kerosene (almost 1000 liters) is transferred per minute. The quantity of fuel carried is calculated by an onboard computer as per the flight route. |
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What You'll Learn
Aircraft fuel tank systems
The position, capacity, and configuration of fuel tanks are determined by an aircraft's specific requirements. Smaller, single-engine aircraft typically feature fuel tanks positioned above the wing, using a gravity feed system for fuel delivery to the engine. Some aircraft have tanks beneath the wing and employ pumps or fuel injection for fuel transport. These tanks can be standalone components or seamlessly integrated into the wing structure.
Integral fuel tanks are constructed within sealed wing regions and consist of non-corrosive aluminium frames. They are the lightest option and offer the most space per unit of weight. These tanks are typically positioned in the unused area inside the wings and require baffles to prevent fuel from splashing into the wings during aircraft manoeuvres. Bladder tanks are made of reinforced flexible materials, such as synthetic rubber, and do not require large cuts into aircraft structures for installation. The tank can be rolled up, inserted through a small opening, and then unfolded to its full size. Rigid fuel tanks are built separately from the aircraft and installed in the wings or fuselage.
During refuelling, up to 800 kilograms of kerosene, or almost 1,000 litres, are transferred into the tanks per minute. The quantity of fuel pumped into the tanks depends on the planned flight route, with the on-board computer calculating the required amount. Long-haul aircraft usually have an additional trim tank in the tail assembly to help stabilise the horizontal position during flight. As the weight of the wing tanks decreases, fuel can be pumped forward from the trim tank to compensate.
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Fuel tank types
The fuel tank is an essential component of an aircraft, and it comes in various designs to accommodate different aircraft types. The three most popular fuel storage options are integral, bladder, and rigid removable fuel tanks.
Integral fuel tanks are constructed within sealed regions of the wings and consist of non-corrosive aluminium frames. They are integral to the aircraft's structure, and nearly all modern aircraft use this type of fuel tank. They are the lightest option and offer the most space per unit of weight. They are typically positioned in the unused area inside the wings of the aircraft. Baffle check valves are used to keep the fuel from splashing into the wings when the aircraft manoeuvres. Integral tanks often feature intelligent fuel systems with in-tank boost pumps, which deliver fuel to the engine when the voltage is positive.
Bladder fuel tanks are made of reinforced flexible materials, such as synthetic rubber. They are similar to rigid tanks but do not require a large opening in the aircraft for installation. The tank can be rolled up, inserted into a small space, and then unfolded to its full size. Bladder tanks must be attached securely and should lie flat and wrinkle-free in the bay to prevent fuel contaminants from settling into the fuel tank sump.
Rigid removable fuel tanks are commonly found in older aircraft models. They are built separately from the aircraft and installed in the wings or fuselage. These tanks are made of materials such as stainless steel or aluminium alloy and are riveted together to prevent leaks. Rigid tanks undergo pressure testing to ensure they don't leak or collapse during flight.
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Fuel tank construction
Fuel tanks are an indispensable component of every aircraft. They are available in various designs to suit different aircraft types. The three most popular fuel storage options are integral, bladder, and rigid removable fuel tanks.
Integral Fuel Tanks
Integral fuel tanks are constructed within sealed regions of the wings and consist of non-corrosive aluminium frames. They are the lightest and offer the most space per unit of weight. Baffle check valves are used to keep the fuel from splashing into the wings when an aircraft manoeuvres. These tanks are typically positioned in the unused area inside the wings.
Rigid Removable Fuel Tanks
Rigid removable fuel tanks are a common feature of many older aircraft models. They are built separately from the aircraft and installed in the wings or fuselage. To prevent leaks, they are made of materials like stainless steel or aluminium alloy and riveted together. Rigid tanks undergo pressure testing to ensure they won't leak or collapse during flight.
Bladder Fuel Tanks
Bladder fuel tanks are made of reinforced flexible materials such as synthetic rubber. They are similar to rigid tanks but do not require large cuts into aircraft structures for installation. The tank can be rolled up, inserted through a small opening, and then unfolded to its full size. Bladder tanks must be attached with clips or other fastening devices and should lie smooth and unwrinkled in the bay.
Trim Tanks
Long-haul aircraft usually have an additional trim tank in the tail assembly. This helps stabilise the horizontal position during flight: as the fill level and weight of the wing tanks decrease, fuel can be pumped forward from the trim tank to compensate.
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Fuel tank safety
Firstly, it is essential to select suitable materials for fuel tanks. They are typically made from resilient materials such as aluminium alloys, composite materials, or, in newer designs, isophthalic polyester resin composite. These tanks are engineered to resist corrosion and leakage, withstanding rigorous conditions such as changes in temperature, pressure, and altitude during flight.
Secondly, proper maintenance and inspection procedures are vital. This includes checking for leaks, cracks, or rust and ensuring that all parts, nuts, clamps, and connectors are securely fastened and free from defects or damage. Maintenance personnel should also check the wiring harnesses and connectors for broken wires or compromised wiring insulation, as this could be a source of fuel leaks and a potential ignition source.
Additionally, strict procedures are in place during refueling to ensure safety. This includes grounding procedures to prevent static electricity buildup, ensuring fuel compatibility, and avoiding overfilling tanks. Interting systems are also employed, replacing oxygen in the tanks with inert gas to prevent fires and explosions. Proper airflow management is critical to preventing vapour buildup and pressure spikes, which can lead to disasters.
Furthermore, the positioning of fuel tanks is carefully considered. Fuel tanks are often placed in the wings to minimize weight-related stresses on the aircraft structure and maximize space efficiency. This design consideration is crucial for the safe operation and efficiency of the aircraft.
Lastly, it is important to note that entering a fuel tank for maintenance or repairs is a deliberate and carefully supervised procedure with significant risks. Adherence to all safety precautions is mandatory to mitigate the potential for accidents, such as fires or other fatal incidents.
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Fuel tank maintenance
Firstly, it is essential to understand the different types of fuel tanks and their unique maintenance requirements. Aircraft fuel tanks vary in design and include integral, bladder, and rigid removable fuel tanks. Integral fuel tanks, the lightest option, are constructed within sealed regions of the wings and consist of non-corrosive aluminium frames. Bladder fuel tanks, on the other hand, are made of reinforced flexible materials, such as synthetic rubber, and offer the advantage of easy installation without requiring large cuts into the aircraft's structure. Rigid removable fuel tanks, commonly found in older aircraft models, are made of materials like stainless steel or aluminium alloy and are riveted together to prevent leaks.
When performing maintenance on fuel tanks, several critical steps must be followed to ensure safety. Before entering a fuel tank, technicians must adhere to standard practices, including defuelling and emptying the tank, deactivating associated aircraft systems, and electrically grounding the aircraft. Additionally, adequate fire protection equipment should be readily available near the repair site. Portable gas detectors are also essential to monitor oxygen and flammable vapour concentrations, with oxygen levels maintained between 19.5% and 23.5% to prevent the risk of fire or explosion.
The interior of a fuel tank can pose hazards due to confined spaces and the presence of toxins or irritants in the jet fuel. Therefore, only trained technicians should enter the fuel tank, and they must maintain constant and accurate voice communication with the team outside. It is crucial to identify, control, and eliminate hazards associated with fuel tank entry, and ergonomic considerations must be made to protect the health and safety of the working personnel.
To ensure the proper functioning of the fuel tank, inspections should include a thorough investigation of the tank's interior, checking for discrepancies. Fuel tanks must be designed, located, and installed to retain fuel when subjected to various stress factors, including vibration, aerodynamic forces, heat, cold, and inertial loads. Ventilation and drainage are also critical aspects of fuel tank maintenance, preventing the accumulation of flammable fluids or vapours.
Overall, fuel tank maintenance in aircraft is a complex and intricate process that requires specialised training and adherence to safety protocols. By following these procedures, technicians can ensure the safe and efficient operation of the aircraft's fuel system.
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Frequently asked questions
An aircraft fuel tank is a critical component of an aircraft's fuel system. It stores and delivers clean fuel to the engine at the correct pressure and flow rate.
There are three main types of aircraft fuel tanks: integral, rigid removable, and bladder. Integral fuel tanks are constructed within the aircraft's structure, typically in the wings, and are the lightest option. Rigid removable fuel tanks are built separately and installed in the wings or fuselage, and bladder fuel tanks are made of reinforced flexible materials and installed in a similar way to rigid tanks.
Aircraft fuel tanks have pumps that deliver fuel to the engines. The number of pumps varies depending on the aircraft, but each tank typically has at least two. The fuel is pumped from the tanks to the main engine-driven fuel pump, and then to the low-pressure fuel valve.
Fuel tanks are often located in the wings to reduce stress and increase efficiency. The weight of the fuel counteracts the wing-bending loads, and placing the tanks in the wings moves them further from passengers and crew in the event of a leak or explosion.
