How Pilots Combat Fuel Leaks

Aircraft fuel system leaks are very hazardous situations as they can lead to fuel tank depletion, cause fires, and generally pose a major safety risk to an aircraft and its passengers. Fuel leaks can happen from a variety of situations such as a fuel tank or fuel line rupture, and various guidelines are given to pilots to assist in determining the affected area. While rare in occurrence and fairly preventable with proper maintenance and aircraft handling, pilots should always know how to quickly identify and combat fuel leaks when they occur for the safety of all on the aircraft.

In order to combat the risks associated with fuel leaks, one should always begin with flight planning and preventative measures. Before departing for a flight, airlines will always craft a flight plan that accounts for weather, airspace restrictions, the aircraft conducting the flight, and other factors. Once an optimal path has been decided upon, the amount of fuel needed for the flight is calculated alongside a gross-error check. The fuel can then be added to the aircraft fuel tank, and the flight management computer will make its fuel estimation which should be the same as the flight plan calculation.

During the duration of the flight, pilots should conduct in-flight fuel checks with the fuel gauge instrument provided in the cockpit. By cross-referencing the amount of fuel remaining within the tanks with the flight plan calculation, one can ensure that all estimates are being met. If fuel is being expended at a much quicker rate than is expected, there may be a problem that needs to be addressed. While the most common explanations are stronger headwinds and weather issues that may not be a concern due to bringing extra fuel, certain conditions may warrant further concern.

One of the first signs that a fuel leak may be occurring is if there are any imbalances between each main wing tank. To determine if there is a fuel leak, one should consider if the remaining fuel is less than what was previously calculated, if the engine has an excessive fuel flow rate, or if the totalizer fuel is less than the calculated fuel. If one determines that the aircraft fuel system is facing a leak, one should not try to balance the tanks as it may cause the situation to become worse. Instead, pilots should follow a fuel leak checklist to combat the issue.

Utilizing the fuel leak checklist, pilots can ascertain if there is a leak and determine where it is coming from. To begin, all tanks should be isolated by switching the balance and crossfeed switches off. Once each tank is separately feeding the engines, fuel quantities can be measured and monitored to find what assembly component is the culprit. If the engine on one side is the issue, shutting it off should solve the problem and a lower altitude may be needed to accommodate the change. If the tank on the shut off side continues to decrease in fuel quantity, it is the fuel tank itself which is the issue. If the engine is at fault, the remaining fuel from the affected side can be used to power the working engine. If the fuel tank is the issue, however, an early landing may be required to ensure safety.

As in-flight fueling is not an option for commercial aviation, it is crucial that all fuel leaks and fuel leak off conditions are caught quickly and remedied as soon as possible. As leaks may be the cause of aging or damaged components that fail under stress, one should always conduct regular inspections and maintenance to maintain the integrity and health of assemblies. For the highest quality aircraft fuel system components that you can steadily rely on, look no further than Aviation Axis.

Aviation Axis is a premier online distributor of aircraft components offering customers competitive prices and rapid lead-times on over 2 billion new, used, and obsolete components. As the only independent distributor with a no China sourcing pledge, we ensure that every purchase ships alongside its qualifying certifications or manufacturing trace documentation. To begin the purchasing process today, we ask that you fill out and submit an Instant RFQ form as provided on our website. Once received, a member of our staff will reach out to you in 15 minutes or less to provide a personalized quote accommodating your individual needs and requirements.


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