Design of a fuel transfer pump for

general aviation aircraft.

Tafadzwa Nigel Ncube (R201971T)

Supervisor: Mr Takawira
Introduction.
Fuel transfer in this case refers to the movement of fuel from the aircraft fuel tanks tsafe storage unit and vise versa.

General aviation (GA) is defined by the International Civil Aviation Organization (ICAO) as all civil aviation aircraft
operations except for commercial air transport or aerial work.

Aircraft defueling is mostly carried out for maintenance purposes.

It can also be done so as to reduce the aircraft weight in order to make it easy for placing it on jacks.

Once maintenance has been carried out there is need to refuel the aircraft.
Background.
For pressure fueled aircraft normally defuel through the pressure fueling port, this is usually for multi crew
aircraft.

Gravity defueling is the process of draining the tanks by opening the drain valves or petcocks of the aircraft fuel
system, this is normal for small aircraft in the general aviation sector.

It is a slow and dangerous process. (Global Security, 2023).

Problem statement.

Defueling through sump tank drains and refueling the aircraft with the fuel by means of a funnel and a special
bucket is time consuming, risks fuel contamination and is a hazard when improperly done.
Aim.
To design and fabricate external portable, cost effective, safe, adequate rate fuel pump prototype which can be
used in fuel transfer for small aircraft for maintenance purposes.
Objectives.

To design a pump which can be used to pump AVGAS or JET A1 aircraft fuels in
compliance with FAA, ICAO and CAAZ regulations.
To design a fuel pump which can pump fuel at a minimum rate of 40 litres per minute.
To design a pump with a maximum static head of 4.5 m
To inc-operate fuel quality monitoring system for the pump, and the use of special filters
to avoid the refueling of contaminated fuel.
To fabricate pump parts instead of ordering already manufactured parts
Questions.
What will be the primary use of the pump?

Why must the pump be used?

Where will the pump be used?

Who will use the pump?

When must the pump be used?

Hypothesis.
The use of a pump to drain and refill small aircraft with fuel will reduce the time and amount of labour required
to perform these tasks.

Proper transfer of fuel from the tank to proper storage facility, has an effect of not compromising the fuel quality
and can be reused.
Timeline.
Chapter Two: Literature Review.
1. Aviation fuel transfer standards and guidelines:
a) As per ICAO, FAA and CAAZ standards.
b) General Guidelines to be followed in fuel maintenance procedures.
2. Pump Technologies and Types:
a)Pump definition and general use
b) Types of pumps
c) Performance of a pump and factors affecting performance.
d) Sources of power
3. Jet A1 and AVGAS chemical and physical properties, contaminants they prone to.
cont…
4. Fuel contamination.
a)Common AVGAS and JET A1 contaminants and effects
b)Case study on Incidents involving contaminants.
c) Technologies in contamination detection.
5. Requirements for an ideal pump for AVGAS/ JET-A1.
a) Operational standards and specifications.
b) Material used for pump the fuel.
c) Safety and environmental considerations requirements.
cont…

6. Critique of pumps used as solutions to the project problem.

Chapter three: Methodology.
Possible solutions.

1. Centrifugal pump.
2. Membrane Pump.
3. Gear pump
Concept selection.

The diaphragm pump was chosen through the

matrix dominance method using the criteria shown
below.
FUNCTION (A)
CONTAMINATION FACTOR (B)
LEAKAGE (C)
EFFICIENCY (D)
NOISE EMISSIONS (E)
EASE OF MANUFACTURE (F)
WEIGHT (G)
ERGONOMICS (H)
COST (I)
LOW MAINTENANCE (J)
%

% A B C D E F G H I J

A % 1 1 1 1 1 1 1 1 1

B 0 % 0 1 1 1 1 1 1 1

C 0 1 % 1 1 1 1 1 1 1

D 0 0 0 % 1 0 1 1 0 0

E 0 0 0 0 % 0 1 1 0 1

F 0 0 0 1 1 % 1 1 0 0

G 0 0 0 0 0 0 % 0 1 0

H 0 0 0 0 0 0 1 % 0 0

I 0 0 0 1 1 1 0 1 % 0

J 0 0 0 1 0 1 1 1 1 %A

E
 Criteria weighing
CONCEPT CONCEPT
RATING WEIGHT
% A B C D E F G H I J Crit Wei Ran CRITE WEIG 1 2 3 1 2 3
A % 1 1 1 1 1 1 1 1 1 eria ght king RIA HT
B 0 % 0 1 1 1 1 1 1 1 A 9 1 A 9 10 8 9 90 72 90
C 0 1 % 1 1 1 1 1 1 1 B 7 3 B 7 6 10 6 42 70 42
D 0 0 0 % 1 0 1 1 0 0 C 8 2 C 8 7 10 6 54 80 48
E 0 0 0 0 % 0 1 1 0 1 D 3 7 D 3 10 7 9 30 21 27
F 0 0 0 1 1 % 1 1 0 0 E 3 7 E 3 8 6 9 24 18 27
G 0 0 0 0 0 0 % 0 1 0 F 4 4 F 4 8 9 8 32 36 32
H 0 0 0 0 0 0 1 % 0 0 G 1 9 G 1 8 6 10 8 6 10
I 0 0 0 1 1 1 0 1 % 0 H 1 9 H 1 10 7 9 10 7 9
J 0 0 0 1 0 1 1 1 1 % I 4 4 I 4 7 9 10 28 36 40
J 4 4 J 4 6 8 7 24 32 28
342 378 353
cont...
The diaphragm pump (CONCEPT 2) which has been chosen from the above matrix. Function, efficiency, low
leakage and contamination capablities are important elements allowing for use of a pump in fuel transfer, hence
for the project to be a success these criteria must be prioritised.
Concept Development.
Description
Power supply.
I order to increase safety in accordance with ICAO, the pump will eliminate the use of electricity as the source of power.
The design will make use of pneumatic power in the form of compressed air. The design will use an air motor as the
source of power. An air motor converts the energy of compressed air to rotational energy this eliminates the risk of
electrical sparks which can cause ignition of the fuel being moved.

Basic power can be calculated using a simple formula: P = M x n / 9550.

Where M is nominal speed

n is nominal rpm.
Reduction gear.
The design will make use of a reduction gear box.

This is a mechanism used to increase the output torque of a motor, but at the same time reducing the out put r.p.m

The output torque of the speed gear reducer is calculated as follows:

Speed ratio = output revolution of motor ÷ output revolution of gear reducer (“speed ratio” is also called “transmission ratio”)

If the motor power, speed ratio and use coefficient is known, the torque of the motor reducer can be calculated as follows:

Torque of gear reducer = 9550 x motor power ÷ motor input revolution x speed ratio x use coefficient.
Reciprocating Action.

For this design the slider crank is incoperated. An arrangement of mechanical parts designed to convert
straight-line motion to rotary motion or to convert rotary motion to straight-line motion.
Diaphragm.

This is an elastic material able deform and return to natural position. This facilitates the changes in volume
with in the pump, and creating pressure differentials which will allow the flow of fluid.
Check valves

The design will inco-operate ball check valves.A ball check valve is a simple and reliable valve with the only
moving part to block the reverse flow, is a spherical ball. The full-ported valve seat is uniquely designed
allowing the ball to seat leak-tight without getting wedge into the valve seat
CASE.

The design will have a two vacuum chambers in order to counter act the reciprocating effects which include a
non continuous flow of fluid.
CONCEPTUAL DESIGN

● The design process and 3D modeling was carried out using AUTOCAD 2007.
● The conceptual design shows the basic appearance and function of the pump.
south west isometric view
front view
side view
top view
reciprocating plus reduction mechanism