Narrative:

Aircraft xyz had a prior write-up for fuel leak left wing. We were called to do a functional check flight. During initial rotation a mechanic observer said we had a substantial amount of fuel streaming from our left wing. We noted that the fuel quantity in the left main tank was decreasing at a significantly faster rate than the right. We had to balance fuel to stay within tolerance. We declared an emergency and returned to ZZZ without any further incident. Callback conversation with reporter revealed the following information: the reporter stated the aircraft had been in a heavy 'C' check and wing panels were removed for various inspections and when the panels were replaced a wing tank plastic vent line inboard of the aileron was dislodged. The reporter said the leak could not be detected on the ground but needed at least 4 degrees nose up to start the leakage. The reporter said the leak rate was approximately one ton per min at a high angle of attack.

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Original NASA ASRS Text

Title: A FOKKER 100 IMMEDIATELY AFTER TKOF AT 3000 FT DECLARED AN EMER AND DIVERTED DUE TO A L WING MASSIVE FUEL LEAK CAUSED BY A DISLODGED FUEL TANK VENT LINE.

Narrative: ACFT XYZ HAD A PRIOR WRITE-UP FOR FUEL LEAK L WING. WE WERE CALLED TO DO A FUNCTIONAL CHK FLT. DURING INITIAL ROTATION A MECH OBSERVER SAID WE HAD A SUBSTANTIAL AMOUNT OF FUEL STREAMING FROM OUR L WING. WE NOTED THAT THE FUEL QUANTITY IN THE L MAIN TANK WAS DECREASING AT A SIGNIFICANTLY FASTER RATE THAN THE R. WE HAD TO BALANCE FUEL TO STAY WITHIN TOLERANCE. WE DECLARED AN EMER AND RETURNED TO ZZZ WITHOUT ANY FURTHER INCIDENT. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED THE ACFT HAD BEEN IN A HVY 'C' CHK AND WING PANELS WERE REMOVED FOR VARIOUS INSPECTIONS AND WHEN THE PANELS WERE REPLACED A WING TANK PLASTIC VENT LINE INBOARD OF THE AILERON WAS DISLODGED. THE RPTR SAID THE LEAK COULD NOT BE DETECTED ON THE GND BUT NEEDED AT LEAST 4 DEGS NOSE UP TO START THE LEAKAGE. THE RPTR SAID THE LEAK RATE WAS APPROX ONE TON PER MIN AT A HIGH ANGLE OF ATTACK.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.