B737-700
Flight Crew Air Transport Pilot (ATP); Flight Crew Instrument; Flight Crew Multiengine
Communication Breakdown
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy; Ground Event / Encounter Other / Unknown
General Flight Cancelled / Delayed
Human Factors; Procedure; Aircraft; Company Policy
We noticed that fueling had stopped approximately 3;000 pounds short of the required amount for our flight. Several minutes later the fueler providing services; documents etc. to our flight stopped in the cockpit to retrieve our release. I questioned him as to why fueling had stopped. He stated the first fuel truck had run short of fuel and the second truck 'had a maintenance issue' and they were working to get a third truck. He left the cockpit and several minutes later fueling began again. At this point the aircraft was fully boarded with passengers; but we noticed once again fueling stopped again short of our required amount; this time by 200 to 300 pounds.I put on a safety vest to go outside and speak to the fueler but upon exiting the aircraft I discovered the aircraft surrounded by the fueler; Fueling Management Personnel; Airport Police; Management; numerous representatives of [the fueling company]; and even Maintenance Personnel. There was a large pool of fuel under the left wing of the aircraft and no visible leak on going. I immediately began to inquire what was going on and was informed that during fueling of the aircraft the automatic shutoff of the left wing tank had failed. The fueler stated that when the shutoff failed they attempted to manually close the fueling valve from the fuel panel but despite the switch being in the closed position the tank continued to fill and overflow.They stopped the overfilling by shutting off the fuel truck itself. This had apparently occurred 15 minutes prior when we noticed the fueling first stop and numerous Airport Personnel were notified but the flight deck crew was never told. I contacted Maintenance Control; who suspected that only the automatic fuel shutoff had failed and the manual shutoff on the panel was improperly operated. In consultation with Maintenance Control and local Maintenance Personnel; the aircraft was tested and it was determined that the both the automatic and manual system had indeed failed due to the fueling valve itself becoming stuck in the open position. The aircraft was deplaned; a logbook entry was made; and the flight was subsequently canceled.I find it a major safety concern that a sizable fuel spill occurred due to an aircraft system malfunction and local ground personnel notified every conceivable individual from the Airport Authority; Police; fueler; local management staff; and even Aircraft Maintenance yet never notified our crew of any issue for at least 15 minutes after it occurred and then only because I; myself; went to the ramp to ask simple questions about our fueling; not because I had the least idea that a fuel leak had ever occurred. I firmly believe [the] local staff and [fueling company] staff need to be reminded that it is absolutely critical that any safety issue with or around the aircraft; in particular one that is boarded with passengers; needs to be identified to the crew first and foremost.
B737-700 Captain reported that a major fuel spill occurred during re-fueling but flight crew was not notified.