CS 29.965 Fuel tank tests

ED Decision 2003/16/RM

(a) Each fuel tank must be able to withstand the applicable pressure tests in this paragraph without failure or leakage. If practicable, test pressures may be applied in a manner simulating the pressure distribution in service.

(b) Each conventional metal tank, each non- metallic tank with walls that are not supported by the rotorcraft structure, and each integral tank must be subjected to a pressure of 24 kPa (3.5 psi) unless the pressure developed during maximum limit acceleration or emergency deceleration with a full tank exceeds this value, in which case a hydrostatic head, or equivalent test, must be applied to duplicate the acceleration loads as far as possible. However, the pressure need not exceed 24 kPa (3.5 psi) on surfaces not exposed to the acceleration loading.

(c) Each non-metallic tank with walls supported by the rotorcraft structure must be subjected to the following tests:

(1) A pressure test of at least 14 kPa (2.0 psi). This test may be conducted on the tank alone in conjunction with the test specified in subparagraph (c)(2).

(2) A pressure test, with the tank mounted in the rotorcraft structure, equal to the load developed by the reaction of the contents, with the tank full, during maximum limit acceleration or emergency deceleration. However, the pressure need not exceed 14 kPa (2.0 psi) on surfaces not exposed to the acceleration loading.

(d) Each tank with large unsupported or unstiffened flat areas, or with other features whose failure or deformation could cause leakage, must be subjected to the following test or its equivalent:

(1) Each complete tank assembly and its supports must be vibration tested while mounted to simulate the actual installation.

(2) The tank assembly must be vibrated for 25 hours while two-thirds full of any suitable fluid. The amplitude of vibration may not be less than 0.8 mm (one thirty-second of an inch), unless otherwise substantiated.

(3) The test frequency of vibration must be as follows:

(i) If no frequency of vibration resulting from any rpm within the normal operating range of engine or rotor system speeds is critical, the test frequency of vibration, in number of cycles per minute, must, unless a frequency based on a more rational analysis is used, be the number obtained by averaging the maximum and minimum power-on engine speeds (rpm) for reciprocating engine powered rotorcraft or 2000 cpm for turbine engine powered rotorcraft.

(ii) If only one frequency of vibration resulting from any rpm within the normal operating range of engine or rotor system speeds is critical, that frequency of vibration must be the test frequency.

(iii) If more than one frequency of vibration resulting from any rpm within the normal operating range of engine or rotor system speeds is critical, the most critical of these frequencies must be the test frequency.

(4) Under sub-paragraph (d)(3)(ii) and (iii), the time of test must be adjusted to accomplish the same number of vibration cycles as would be accomplished in 25 hours at the frequency specified in sub-paragraph (d)(3)(i).

(5) During the test the tank assembly must be rocked at the rate of 16 to 20 complete cycles per minute through an angle of 15° on both sides of the horizontal (30° total), about the most critical axis, for 25 hours. If motion about more than one axis is likely to be critical, the tank must be rocked about each critical axis for 12½ hours.