Until we figure out a way to power our airplanes by electricity, sunlight, or nuclear reactors, we will rely on fossil fuel. I will limit this discussion to airplanes that use either avgas or automotive gasoline. I will refer to these collectively as fuel.
When the clean fuel flows to the engine there is lots of noise and everyone is happy. When the fuel is contaminated there may be short interludes of quiet followed by prolonged silence, bar the screaming of terrified passengers. The silence is likely to soon be broken by the sound of bending aluminum. Not good.
So how does fuel become contaminated and with what? Water, sediments, or other foreign substances can enter the system and cause problems. There is also the possibility of adding jet fuel rather than gasoline. (That one can be easily avoided by insisting on personally supervising the fueling of the airplane and matching the label on the truck or fuel farm with the placards near the airplane's filler openings.) Update courtesy of Dan M.: "One can check for jet fuel by pouring a few drops from the sample on white paper (like the edge of a sectional). Very quickly it will vaporize and not leave any trace on the paper if there is no jet fuel mixed in. If there is even a tiny amount of jet fuel it will leave a stain that will not go away. I always do this when fueling at places that have jet fuel on the premises, no matter what the sign on the truck says." Thanks, Dan! Great idea.
Water is the most common contaminant. It can be introduced through the addition of fuel already contaminated with water. This is rare if purchasing fuel from a reputable FBO who complies with regulations regarding filter maintenance and system testing. But, failure of even the best operations is possible. Using a can to transport fuel to an airplane is a more common cause.
More likely the water entered the fuel tank through a leaky cap. The recessed fuel caps of the high performance airplanes are the most susceptible. They should be thoroughly inspected by a qualified technician on a regular basis and rebuilt or replaced promptly if a problem is noted. Water can also enter a fuel tank due to condensation in a partially filled tank. Keeping the tanks filled when the airplane is parked will help mitigate this problem but that isn't always possible due to takeoff weight restrictions.
Sediment and other foreign substances can enter the tank from the fueling source. Again, this is rare if fueling is done by a reputable operator and not so rare if fueling from a can. Most aircraft fuel caps cannot be locked and sabotage is not as uncommon as one may think. That happened at a flight school I was associated with some years ago. A flight instructor broke up with his girlfriend and she decided to teach him a lesson by pouring sand into the fuel tanks of our low-wing fleet. It was detected before anybody flew because she wasn't very precise and spilled sand on all the wings. This was before most airports were fenced and access was limited, but it's still pretty easy to get onto the ramp at many smaller GA airports.
Contamination of solids can come from within the tank. I have seen sealants decompose and contaminate the fuel. There is also the possibility of biological contamination in terms of microbes, bacteria, and fungi. This is more common in jet fuel, but I personally encountered it once in avgas. Any debris is bad. A few large pieces or many small pieces can clog up the fuel system.
So what to do? Sample, sample, and sample some more. The first flight of the day must be preceded by taking a sample from each fuel drain. Sometimes that can be quite a task depending on how many fuel drains an airplane has. (Do you know for sure how many fuel drains your airplane has?) As the day progresses, each tank to which fuel has been added must be sampled before flight, but long enough after fueling to allow any water or sediment to settle. Water is detected because it is heavier than fuel and will produce a defined line between fuel and water in the sampler. If the tint of the fuel isn't clearly visible, sniff the sampler to make sure it contains fuel and not all water. I have had many occasions when the first sample or two contained not fuel at all, just water. Solids can generally be seen in the bottom of the sampler or by a general discoloration of the sample. It's a good idea to wipe off the fuel drains before sampling to avoid false positives from debris kicked up by tires.
Is it possible to get a clean fuel sample and still have water in the system? You bet it is! I have seen that more times than I can count. Sometimes the water hides in the tanks. Single engine Cessnas have been particularly prone to this due to the small dihedral in the wings. Most light GA airplanes have "wet wings" using an integral aluminum tank. Some airplanes use flexible bladders. A pilot also recently told me that he had the recurring water problem once and they found that there was a wrinkle in a fuel bladder providing a place for the fuel to hide. Some airplane manuals instruct us to perform a "rock and roll" procedure in which the airplane is rocked from side to side and tail-down to loosen any trapped water and allow it to reach the drain points. Conventional procedure is to keep draining till the sample is entirely fuel. I would suggest caution after clearing water. I would do some more "rock and roll" and then wait at least 15 minutes to give time for the water to find the lowest point before taking another sample.
So in summary, pilots should take every possible precaution to prevent contamination from entering the fuel system. Once it is there, no matter how slight, we must make sure it is out before flight.
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