AD/A320/192 Main Fuel Pump System Airworthiness Limitation (Cth)

AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (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 Main Fuel Pump System - Airworthiness Limitation 7/2006 TX

Applicability:

AIRBUS A318, A319, A320 and A321 aircraft, all models, all serial numbers that are equipped with fuel pumps manufactured by Eaton Aerospace Limited (formerly FR-HITEMP limited) part number (PN) 568-1-27202-005 with a serial number from 6137 and above.

Requirement:

1. Incorporate Aircraft Flight Manual (AFM) Temporary Revision AFM TR 4.03.00/28 into the AFM or insert a copy of this AD into the AFM Limitations section:

Applicable to all aircraft:

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 700 kg (1550 lb) 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 2,000 kg (4,500 lb) 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 (1550 lb).  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 2,000 kg (4,500 lb) 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.

Limitations applicable to aircraft fitted with centre tank (mod 20024) excluding A321 aircraft all models:

CENTRE TANK PUMPS OPERATION PROCEDURE:

WARNING:

Do not turn on the centre tank pumps when the centre tank contains less than 2,000 kg (4,500 Ib) 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 12,000 kg (26,500 lb)

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 12,000 kg (26,500 lb)

On ground, after refuelling:

·    Check that the centre tank contains at least 2,000 kg (4,500 lb) of fuel.

Note:  If the fuel quantity is less than 2,000 kg (4,500 lb), 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 3,000 kg (6,500 lb), 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 (4,500 lb) and 3,000 kg (6,500 lb):

·    Turn FUEL MODE SEL to MAN.

·    Turn or maintain off both centre tank pumps.

Note:  In flight, if the fuel quantity in the centre tank decreases below 2,000 kg (4,500 lb) and centre tank pumps have not been turned off, then:

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 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 off 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 5,000 kg (11,000 lb):

·    Turn on both centre tank pumps.

·    When FUEL CTR TK PUMP 1 or PUMP 2 or PUMPS LO PR is triggered on the ECAM or the centre tank is empty.

·    Turn off both centre tank pumps.

CAUTION
Turn off both centre tank pumps without delay.

Note:  EASA EAD 2006-0106-E dated 2 May 2006 refers.

Compliance:

From the effective date of this AD unless:

-  centre tank pumps are identified as not in the affected batch, or

-  centre tank is de-activated and empty and remains so.

This Airworthiness Directive becomes effective on 8 May 2006.

Background:

An operator reported a failure of this type of fuel pump 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.

Installation of pumps with a different PN and/or pumps PN 568-1-27202-005 with a serial number outside the batch defined in the applicability of the AD is considered a terminating action of this AD.

James Coyne
Delegate of the Civil Aviation Safety Authority

4 May 2006