AD/A320/192 Amdt 2 Main Fuel Pump System Airworthiness Limitations and Modifications (Cth)

AIRWORTHINESS DIRECTIVE

On the effective date specified below, and for the reasons set out in the background section, the CASA delegate whose signature appears below revokes Airworthiness Directive (AD) AD/A320/192 Amdt 1 and issues the following AD under subregulation 39.001(1) of CASR 1998.  The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

Airbus Industrie A319, A320 and A321 Series Aeroplanes

AD/A320/192 Amdt 2 Main Fuel Pump System - Airworthiness Limitations and Modifications 10/2007

Applicability:

A318, A319, A320 and A321 aeroplanes, all models, all serial numbers except those that have Airbus modification 37508 incorporated during production or Airbus Service Bulletin (SB) A320-28-1159 dated 8 January 2007, or later EASA approved revision, embodied whilst in service.

Requirement:

1.    The following refuelling limitations/procedures are rendered mandatory:

a.     Refuelling:

·    Before refuelling, all pumps must be turned off in order to prevent them from automatically starting during the refuelling process.

b.    Ground fuel transfer:

·    For all aircraft, do not start a fuel transfer from any wing tank, if it contains less than 700kg (1,550lb) of fuel.

·    For A318, A319 and A320 aircraft with a centre tank, do not start a fuel transfer from the centre tank if it contains less than 2,000kg (4,500lb) of fuel.

·    If a tank has less than the required quantity it is necessary to add fuel (via a transfer from another tank or refuelling) to enable a transfer to take place.

c.     Defuelling:

·    For all aircraft, when defuelling the wings do not start the fuel pumps if the fuel quantity in the inner tank (wing tank for A321) is below 700 kg (1,550lb).  If the fuel on the aircraft is not sufficient to achieve the required fuel distribution, then transfer fuel or refuel the aircraft to obtain the required fuel quantity in the wing tank.

·     For A318, A319 and A320 aircraft with a centre tank, when performing a pressure defuel of the centre tank, make sure that the centre tank contains at least 2,000kg (4,500lb) of fuel.  If it has less than the required quantity, then transfer fuel to the centre tank.  Defuel the aircraft normally, and turn OFF the centre tank pumps immediately after the FAULT light on the corresponding pushbutton-switch comes on.

2.    All aircraft, except A321 series, fitted with a centre tank (Modification 20024) - Amend the Aircraft Flight Manual (AFM) and the Aircraft Operating Manual (AOM) by either inserting AFM temporary revision TR 4.03.00/28 issue 02 or a copy of this Directive in the Limitations Section.

OPERATION OF CENTER TANK PUMPS

If it is confirmed by the maintenance/engineering personnel that the flight is going to be performed with:
- centre tank pumps not in the affected batch, or
- centre tank de-activated in accordance with AMM task 28-21-00-040-00200,
then, the following procedure does not apply.

CENTRE TANK PUMPS OPERATION PROCEDURE

WARNING:
Do not turn on the centre tank pumps when the centre tank contains less than 2,000kg (4,500lb) of fuel, even if it is requested by another procedure.

Before and during refuelling, turn all tank pumps off.

■     If the total Fuel On Board (FOB) after refuelling is less than or equal to 12,000kg (26,500lb):

On ground, after refuelling:

Check that the centre tank is empty.
Note: If it is not empty, the fuel contained in the centre tank must be considered unusable.
Turn on all wing tank pumps
Maintain both centre tank pumps off
Turn FUEL MODE SEL to MAN

■     If the total FOB after refuelling is more than 12,000kg (26,500lb)

On ground, after refuelling:

Check that the centre tank contains at least 2,000kg (4,500lb) of fuel.
Note: If the fuel quantity is less than 2,000kg (4,500lb), leave both centre tank pumps off for the rest of the flight, consider centre tank fuel unusable and do not apply subsequent procedures.
Turn on all wing tank pumps if the fuel quantity in the centre tank is above 3,000kg (6,500lb), turn on both centre tank pumps.

Monitor the fuel quantity in the centre tank.

   ●          When the fuel quantity in the centre tank is between 2,000 kg (4,500lb) and 3,000kg (6,500 lb):

Turn FUEL MODE SEL to MAN
Turn or maintain off both centre tank pumps

Note: If the fuel quantity in the centre tank inadvertently gets below 2,000kg (4,500lb) prior to being checked and centre tank pumps have not been turned off, the flight crew must perform the following steps:

• If the fuel in the centre tank is required for the flight, leave the centre tank pumps in ON position and turn FUEL MODE SEL to MAN.  When FUEL CTR TK PUMP 1 or PUMP 2 or PUMPS LO PR is triggered on the ECAM, or, when the centre tank is empty, turn off the centre tank pumps without delay. Do not apply the subsequent procedures.
• If the fuel in the centre tank is not required for the flight, turn of both centre tank pumps and do not turn them back on for the rest of the flight. Consider the centre tank fuel unusable.  Do not apply the subsequent procedures.

● When FUEL AUTO FEED FAULT is triggered on the ECAM, or the fuel quantity in one wing tank (inner + outer) is below 5,000kg (11,000lb):

Turn on both centre tank pumps

● If FUEL CTR TK PUMP 1(2) LO PR is triggered on the ECAM:

Turn off the associated centre tank pump

CAUTION
Turn off associated centre tank pumps without delay.

● If no fuel leak:

Open the crossfeed valve.

● When FUEL CTR TK PUMPS LO PR is triggered on the ECAM, or when the centre tank is empty:

Turn off both centre tank pumps and close the crossfeed valve

CAUTION
Turn off associated centre tank pumps without delay.

3.    Check the part number (P/N) of the fuel pumps and, if necessary, modify and/or replace the pumps, in accordance with the instructions in SB A320-28-1159 or later EASA approved revision.

The installation of fuel pumps modified in accordance with SB A320-28-1159, or later EASA approved revision, at all applicable locations negates the Requirement 1 and 2 limitations and the AFM/FOM amendment may be removed.

4.    Eaton type 8410 fuel pumps P/N 568-1-27202-001, 568-1-27202-002 or
568-1-27202-005 shall not be installed on the aircraft included in the applicability statement of this Amendment.

Note:  EASA AD 2007-0218 refers.

Compliance:

For Requirement 1 - As of the effective date of this Amendment until Requirement 3 is complied with.

For Requirement 2 - Within seven days after the effective date of this Amendment.

For Requirement 3 - Within the next 5,000 hours time in service or 18 months after the effective date of this Amendment, whichever occurs first.

For Requirement 4 - After 27 March 2009.

This Amendment becomes effective on 27 September 2007.

Background:

An operator reported a failure of a type 8410 fuel pump P/N 568-1-27202-005 in service.  Subsequent investigation revealed that the cause of the pump failure was that one of the two screws and nuts holding the gas return connector to the top of the motor housing had become unscrewed.  The screw dropped between the motor rotor and the stator where it caused the short circuit resulting in the circuit breaker tripping.  Further investigation concluded that this was due to the inadequate locking mechanism of the nut and the screw being incorrectly torque tightened.

Consequently, the integrity of the pump’s explosion proof housing is not kept and arcing may occur during the failure.  In case the pump is not submerged in fuel, an explosion could occur both in-flight or on ground.  As a result the original issue of this directive mandated airworthiness limitations

Subsequently, Amendment 1 was issued which continued the airworthiness limitations and mandated the modification of affected pumps.

The European Aviation Safety Agency (EASA) has advised that further investigations have revealed that all of the type 8410 fuel pumps P/N 568-1-27202-001,
PN 568-1-27202-002 and PN 568-1-27202-005 can be affected and this Amendment in addition to airworthiness limitations, enlarges the applicability, and mandates the modification/replacement of affected pumps.

The original issue of this Directive became effective on 8 May 2006.

Amendment 1 of this Directive became effective on 28 September 2006.

Charles Lenarcic
Delegate of the Civil Aviation Safety Authority

17 August 2007