D&C’s Due to Suspected Engine Fuel Leaks

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Overview

Suspected fuel leakage currently #1 cause of D&C’s

CFM/Boeing working to reduce disruptions due to suspected

fuel leaks

These efforts include:

• Communicating available LRU sealing improvements
• Recent FCOM changes addressing leakage noted during engine start
• Clarified guidance for leaks noted during pre-flight walk-around….in-
process

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CFM56-7B Delay and Cancellation Top Causes

Suspected fuel leaks #1 D&C cause; majority “no fault found”

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Fuel Leak D&C Breakdown

Fuel Leak Related D&C

Engine Start Pre-Flight

Resu lt s Resu lt s

Leak in Limits Leak in Limits

Leaks can be noted by crew during walk-around or by

ground support personnel during engine start;
troubleshooting determines serviceability
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Overnight Leakage from Drain

Both Engine HPSOV and Airframe Pylon Valve closed on

shutdown forming a “closed” system
• Hot fuel (normal to system operation) occupies the closed system
volume at ambient pressure.

Given overnight cool down period, the fuel in the closed system
cools and thus its volume decreases.
Vacuum effect on all seals and o-rings from fuel system
 Possible unseating of seals allowing static leakage

AMM 71-71-00-200-801-F00 Engine Vents and Drains Inspection

5 minutes idle run set all seals back in seated position

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Leaks noted during engine start

Boeing will release FCOM revision this month to

clarify that leaks which stop within 5 minute
ground idle run are acceptable
Intent is to avoid maintenance personnel
involvement until leakage confirmed

Engine Start Procedure Normal Considerations

If, during engine start, the ground crew reports a fuel leak from
an engine drain, continue to run the engine at idle for up to 5
minutes. If the fuel leak stops during this time, no maintenance
action is needed. If the fuel leak continues after 5 minutes,
shut down the engine for maintenance action.

FCOM revision should reduce D&C’s due to leaks

noted during starting
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Leaks noted during crew pre-flight exterior
inspection walk-around

Largest opportunity to reduce disruptions

FCOM currently has zero leakage allowance
…not consistent with AMM

• Exterior Inspection
• “Use the detailed inspection…to check that:
• the surfaces and structures are clear, not
damaged, not missing parts and there are
no fluid leaks. ”

CFM/Boeing working to identify improvement opportunities which:

• Respect roles/responsibilities of flight crew, ground support and maintenance
organizations ….. including differences amongst operators

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LRU improvements related to leaks

CFM has introduced sealing improvements as

part of continuous improvement efforts
Recommend these Service Bulletins be
implemented to maximize LRU time-on-wing
capability

HMU
SB 73-0096: O-ring packings changed from fluorosilicone to fluorocarbon at
P11/P12 part introduction in 10/2004.

HPTACC Valve
SB 75-0036: Seal material improvements, along with piston surface finish
changes and seal carrier Teflon coating introduced in 6/2005

TBV
SB 75-0040: Lessons learned from HPTACC improvement incorporated into
the TBV 5/2008.

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Summary

Suspected fuel leakage is currently #1 cause of D&C’s

Majority of suspected leaks are no-fault found based on

available data

Recent FCOM revision provides clarification to avoid D&C’s for

leaks noted during engine starting which subside with
allowance time

Team now focused on identifying similar clarifications to

reduce maintenance burden associated with suspected leaks
found during engine walk-around
– Goal is 3Q15 availability

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