Chapter 40 Fault Simulation for Aircraft Fuel System. Using Flowmaster Ruofan Liu, Cunbao Ma and Hongkai Jiang Abstract The common failures of aircraft fuel system under different conditions. are explored, and a model of aircraft fuel system is established. according to the working principle and composition of B737-300 aircraft, fuel system. By using the Flowmaster tool for completing the simulation and based on the operation of the fuel system in the unhealthy condition, the running result, and the influence of the fuel system are obtained under different malfunction. Keywords Fuel system - Sintulation of the faults - Transient simulation - Flowmaster 40.1 Introduction Aircraft fuel system is one of the main aircraft systems, and the plane’s flight safety is influenced by the working performance. The fuel system is used for storage and providing fuel for engine and APU, it consisted of storage, fuel supply, distribution, pumping, and instructions, etc. The B737-300 aircraft fuel system is introduced in this paper, as well as the method of fault diagnosis of aircraft fuel system, the simulation methods, and results provide effective tools for study of fuel system. Flowmaster software is one-dimensional fluid system simulation software and engineering fluid system simulation software [1], it can be used in stereo system for system level modeling, simulation calculation, and the analysis of the results. In order to analyze the aircraft fuel system and provide valuable reference for the operation of the fuel system maintenance, Flowmaster software is irre- placeable [4. R. Liu (I). C. Ma - H. Jiang School of Aeronautics, Northwestern Polytechnical University, Xivan 710072, Shaanxi, China e-mail: 798535083 @ag.com; 13484466072 163.com J. Wang (ed.), Proceedings of the First Symposium on Aviation Maintenance 353 and Management-Volume 1, Lecture Notes in Electrical Engineering 296, DOK: 10.1007/978-3-642-54236-7_40, © Springer-Verlag Berlin Heidelberg 2014354 R. Liu et al 40.2 System Modeling B737-300 fuel system (Fig. 40.1) is mainly composed of several subsystems of the following: fuel tank, ventilation system, fuel supply system, pumping system, fuel delivery system, measurement, and indicator system. The subsystem is composed. of fuel tank, pipelines, booster pump, valves, and other accessories [2]. 40.2.1 Refueling/Pumping System Model (1) Refueling model The refueling system is composed of part 16, 17, 18, and 40 and 41 (Fig. 40.1); the main effect is to encourage the fuel system. The constant voltage element is used to simulate the refueling system model (3). (2) Pumping model The pumping system is composed of Part 36, 37, 38, 39, and 28, as shown in Fig. 40.1. and the pumping system is to remove the remaining fuel in the tank. All valves should be turned off except part 36, 37, 38, 28, then the booster pump should be started in the fuel tank, the remaining fuel in the tank can be pulled out, 40.2.2 Cross-Feed System Model The main component of cross-feed systema is cross-feed vaive, under normal cir- cumstances, cross-feed valve must be closed, and the corresponding engines should be supplied fuel by cach fuel systems. Only when one of the main fuel system could not work to the corresponding power system, the connected switch of the cross-feed valve enable to turn to the open position, the power system can be supplied fuel by another main fuel system, the above operation ensure the balance of the airplane flight. A valve component (part 76) is used in the cross-feed system model, connecting the two engines. 40.2.3 Tank of Fuel Supply System Model As shown in Fig. 40.1, parts 1, 4, 5. 19, 20, 21 that compose the right tank of fuel supply system, the main effect is to supply fuel to the right engine. Part 2, 6, 7. 8, 22, 23, 29, 30, 31 that compose the central tank of fuel supply system, the central tank contains three booster pumps, the right booster pump supply fuel to the right engine, the left supply fuel to the left engine [7]. The left tank of fuel supply system is composed of parts 3, 9, 10, 25, 26, 27, when cross-feed valve is closed:40 Fault Simulation for Aircraft Fuel System Using Flowmaster 335 tase 26 gett Fig. 40.1 Fuel system model the main task is to supply fuel to the left engine. Because the left tank modeling theory and tbe actual operation principle are consistent with the right fuel supply system, here only the right fuel tank of fuel supply system is given in this paper. 46.2.4 Engine Model (@) Two main engines . The left engine and the right engine are composed of part 12, 14, 34, and part 11, 13, 32 (see in Fig, 40.1), its main role is to provide power for the aircraft flight. “Because Flowmaster is mainly used to study the fluid pipe network system, not to provide a better model of the engine, so an auxiliary fuel tank takes the place of the engine, for both of them have a similar point: engine’s main operation is to consume the fuel, auxiliary tank’s function is to store the fuel, and the process for356 R Livetal ‘Table 40.1, Main Components of Simulation Model ‘Component number Component Component Component number : 1 Refueling system 13 Second tank 94. Center tank “4 First tank 7 Booster pump (right tank) 42, 45. The right spare pump tank 2,04 Booster pump (center tank) 60 Booster pump (left tank) 71,74 . Engine booster pump 10, 73 Engine oo APU 28, 29,75 One-wayvalve 76 Pumping valve 8 Cross-feed vaive 18, 20, 27, 32, 34,38. Pump control components Others Pipeline, valve, connectors the fuel system of auxiliary fuel storage tank is equivalent to the fuel consumption, therefore, an auxiliary fuel tank model is used to replace the engine (parts 70). (2) APU The APU is composed of part 15 and 35 in fuel system, it is also replaced by an auxiliary fuel tank model (part 69), and the modeling principle is the same as the engine model. Connecting the models above, a simplified fuel system simulation model of B737-300 is made up. Simulation model of main components are in the following Table 40.1 [3]. 40.3 Simulation and Analysis Flowmaster contains control element, it can use a contro! element to set these failures. This article discusses several typical faults: fuel leakage, fuel filter clogging, and pump failure. Some notes to the simulation environment are as follows: (1) In this paper, the computation of simulation is transient, so the simulation mode is “Incompressible Transient.” (2) Setting the time step of | s, the simulation start time is 0 s and end time is 1000 s; (3) The result of the operation is negative, it indicates that fluid flow into the element, if the result is positive, suggesting that the fluid flow out of components. (4) In this paper, the simulation model is under the condition that the plane flies at a fixed height, because at different heights, the basic method is similar. For convenience, the simulation height is zero, (5) Because related technology parameters of B-737 fuel system are hard to find, this article’s. main parameters are not entirely accurate, but not too different.40 Fault Simulation for Aircraft Fuel System Using Flowmaster 387 semi C52 Arn, 2 Flow Rate (Volumetric ). Time Pith NEL TAH) ‘encom ems C57 Art 2 Flow Rate (Volumetric Flow Rate) v. Time (1-7) bs 3 Flow Rate (Volumetiic Flow Rate) sg 9 8 Time Fig. 40.2. Flow rate of first tank under normal and fuel leakage condition (6) For convenience, in this paper, based on the basic functions of the fuel system, the mode] is simplified, but the basic ideas are correct. 40.3.1 The Local Influence of the Fuel System by Fuel Leakage Figure 40.2 is the first tank’s ow rate, as shown in Fig. 40.2, fuel flow from the tank, and the flow rate decreases until it is stable, From beginning to end, the flow rate, which is under normal condition, is slightly Jarger than the rate under leakage condition [5]. As-a result of the fuel leakage from first tank, there is a rapid decline in fuel quantity, thus causing a decrease of flow rate [8]. Figure 40.3 shows the fuel pressure at the first tank exit. ‘The pressure of the tank exit, which is under normal condition, is slightly larger than the pressure under leakage condition, This is because in the condition of the leakage, the fuel at the reduced rate is significantly less than the normal, so the pressure will be smaller [8]. 40.3.2 The Influence of Engine by Fuel Filter Clogging The curves 1, 2,3 in Fig. 40.4, are the flow curve in valve opening of 1, 0.5, and 0.1. With the difference between the valve opening values, it indicates that the degree of the fuel filter clogging is diversity. A comparison is made between the fuel supply which the system’s valve opening is 1, 0.5, and 0.1 for right engine. Then the different influences of engine by fue) filter clogging are analyzed [61.358 R. Liu et al «summa wemeems N33 Node: Pressure (Pressure) v. Tire (ERIE 193_4) GSN Nase Prose Presse). Te ia ANETTA tes, Ba s S g 10- = 2 ©09 = Sos — - g 4 £07 =| ® B08 Coo oo 4 2 ° 200 400 800 1000 Time Fig. 40.3 Flow pressure of first tank under normal and fuel Jeakage condition meee cme C70 Arm: 1 Flow Roto (Volumetric Flow Rats) Time (11 8 sme C70 Amn: Flow Rate (Volumetric Flow Rate) v. Time [. 5} € ‘examen €70 Aim 4 Flow Rete (Volumetric FlowRato)v. Time [0.1 3 I : 2.90 § 266 300m g § 205m. § 310m & 3.5m g E 320m : & 400 600 300 1000 x Time Fig. 40.4 Flow rate of different valve opening value. Curve I valve opening value of 13 Curve 2 valve opening value of 0.5; Curve 3 valve opening value of 0.1 Informed by Fig. 40.4, when the valve opening value is 1, 0.5, and 0.1, the fuel filter clogging degree gradually increases, fuel flow to the right engine decreases. However, when the valve opening value goes down from J to 0.5, the fuel flow rate only have small amplitude decreases, when the valve opening value goes down from 0.5 to 0.1, the fuel flow rate is greatly reduced. Thus, the higher degree of clogging, fuel system is more sensitive to fuel filter clogging [6].40 Favit Simulation for Aircraft Fuel System Using Flowmaster 359 4 "60 Aim: 2 Flow Rete {Volumetic)v. Time FE-PE! PERI} 8 mma C60 Arm: 2 Flow Rate (Vokimetric Flow Rate) v. Time GEARS 47 ] —— B 30m = 3 | 1 E 25m 1 2 20m + 815m t 5 10m: = 05m 3 EOE a a re rir ee 2 ° 200 400 600 800 +000 Timess> Fig. 40.5 Flow rate of booster purnp. Curve / Flow rate at normal condition; Crrve 2 Flow rate at booster bump failure condition (NAO Node: Pressure (Pressure) v. Te FE-PE HEH co5_4) (eae N40 Node’ Pressure (Pressure) ¥ Time EPEAT 105 3) 10 405. 100) 098 090 088 080. 975 are O10 200 ado 400 S20 gD TsO OD 1000 ee Timecs> Node: Pressure (Pressura}ebar> Fig. 40.6 Fuel pressure of booster pump exit. Curve 3 Flow pressure at normal condition; Curve 4 Flow pressure at booster bump failure condition 40.3.3 The Local Influence of the Fuel System by Booster Pump Failure : Figures 40.5 and 40.6 shows the fuel flow rate and the fuel pressure, which are under normal and pump fault conditions. The booster pump failure makes the fuel flow and pressure decrease suddenly. By comparing the data in the curve, the sudden failure of fuel pump can cause the decrease of fuel which flows to the engine from the first tank, and ultimately unable to supply fuel to the engine. By this time the engines rely mainly on the central fuel tank, in order to ensure the ‘normal operation of the left engine, the fuel provided from central fuel tank will inevitably increase.360 R. Liu et al, 40.4 Conclusion This paper has described an approach to the model aircraft fuel system, and make fault simulation of the fuel system under ideal condition; it proves that using Flowmaster to simulate aircraft fuel system is feasible. Meanwhile, effective technical support can be provided by fault simulation anc-analysis for aircraft fuel system that improve the safety and reliability of large-type passenger aircraft, Moreover, the study of aircraft fuel system can be facilitated by fuel system fault modeling and simulation, the research process is expedited and costs will be reduced. References . Qiao Y (2007) Aircraft fuel system intelligent fault diagnosis methods. NWPU. Xian, Shanxi, Chins (in Chinese) 2. Fan K (2007) Fuel system of flight simulator modeling and simulating. HIT. Harbin, Heilongjiang, China 3. Feng Z, Gao H, Liu Y (2007) A certain type of aircraft fuel system numerical modeling method and simulation analysis. Aircraft Design 27(5) (in Chinese) 4. Yan K (2008). Helicopter fuel system simulation based on Flowmaster Sofiware. Helicopter Tech O4:1-4 (in Chinese) 5, Qin W, Jia Q (2011) The development of sofiware for aircraft fuel system fault diagnosis, Comput Meas Control 3:1-3 (in Chinese) 6. Lv ¥ (2006) Aircraft fuel system calculation and research, NWPU. Xi'an Shannxi, China (in Chinese) 7. Gavel H (2007) Aircraft fuel system synthesis aided by interactive morphorny and optimization, In: ATAA Aerospace Science Meeting and Exhibit, vol 12, pp 1-3 8. Gao T (2009) The Boeing 737 Aircraft Fuel System Leakage Analysis and Processing. Aviation Maintenance and Engineering, vol 5, pp 14