This chapter contains safety procedures and require- ments that are either general in nature and therefore not covered by the other chapters of this manual or are extremely important and repeated here for emphasis. Safety requirements emphasized in U.S. Marine Corps Technical Manual, TM-3835-15/1, have been incorpo- rated in this chapter. Any departure from the procedures of this chapter may adversely affect the overall safety of the operation being performed.
Although the procedures and requirements con- tained in this manual are as complete as possible, they are no substitute for thorough knowledge of aviation fuels and their inherent characteristics and dangers. All aviation fuels personnel shall therefore be completely familiar with the information contained in MIL- HDBK-844(AS), Technical Manual TM-3835-15/1, and equipment associated publications/ directives. Refueling personnel can best avoid or correct unsafe situations by knowing and understanding aviation fuel hazards.
The development of safe and efficient fuel handling and aircraft refueling procedures is a continuously evolving process. Therefore, standard operating proce- dures (SOPs) governing fuel handling operations in a field environment shall be published and reviewed annually.
Scientific investigations are coupled with actual field experience in order to establish the safest and simplest procedures possible. One of our most impor- tant sources of information in this process is the investigation of field accidents or problems. Therefore, it is extremely important that knowledgeable personnel be involved in accident investigations, especially whenever explosions or fires have occurred. Units should therefore request the assistance and participation of experts whenever major fuel related accidents are being investigated to ensure that correct conclusions are drawn. NAVAIR and NAVPETOFF can assist in the identification of appropriate experts.
16.2 ELIMINATING SOURCES OF IGNITION 16.2.1 Reducing Electrostatic Charges. One of the primary sources of ignition is static electricity.
To ensure the safe relaxation of static charges relevant to fuel operations, all units shall:
1. Prohibit the top loading or splash filling of any rigid fuel vessel; e.g., M970, Aviation Refueling Capability (ARC), or SIXCON fuel tanks. 2. Refill filter or monitor vessels slowly whenever
they have been drained.
3. Keep tanks free of foreign objects that may become unbonded charge collectors; e.g., small conductive objects that can be floated by foaming fuel.
4. Always electrically bond the refueling equipment to the aircraft or truck into which the fuel is being loaded.
Note
All static electrical grounding points used for grounding aircraft during refueling (hot or cold) shall be tested after establishing the refueling point and checked weekly to ensure a 10,000 ohm or less resistance. Aircraft-refueling points shall be tested weekly, or when any change occurs in the status of the grounding point (movement of grounding rod, change of static grounding reel, etc.), to ensure a 10,000 ohm or less resistance is maintained. If testing equip- ment is unavailable, refer to MIL- HDBK-274 for grounding procedures. 5. Ground for all hot refueling operations.
6. Bond refueling nozzles to the aircraft or truck into which the fuel is being loaded using a separate bonding pig-tail before tank caps are removed. This is absolutely critical for overwing (gravity) refueling nozzles since this is the only way to ensure metal-to-metal contact between the refuel- ing nozzle and the aircraft throughout the refuel- ing operation.
7. Attach bonding cables to aircraft using plug and jack method whenever available.
8. Inspect bonding and grounding cables, clamps, and plugs daily basis.
9. Check the electrical resistance of cables and pig-tails monthly. Replace if defective.
10. Do not conduct fuel operations during electrical storms.
11. Remove refuelers from aircraft parking areas during electrical storms.
12. Ground all individual components that require grounding (3″ meter, pump, filter-separator, mon- itor, etc.).
Note
All individual components requiring grounding that are in place for more than a 10-day period shall be tested to ensure a 10,000 ohm or less resistance is maintained. Component grounding points shall be tested monthly or when any change occurs in the status of the grounding point (movement of grounding rod, change of component, grounding cable, etc.) to ensure a 10,000 ohm or less resistance is maintained. If testing equipment is unavailable, refer to MIL-HDBK-274 for grounding procedures. 13. When providing grounds for use by mobile
refueling equipment (ARC, M970, SIXCON, etc.) for the purpose of refueling aircraft, individ- ual verification of each separate aircraft ground- ing point is not required. Instead, a generalized verification shall be conducted in the geographi- cal location (FARP site, FOB, etc.) to ensure a suitable ground (less than 10,000 ohms resist- ance) can be maintained. Mobile refueling equipment parking area grounding points shall be checked prior to being used and verified weekly or when any change occurs in the status of the grounding point.
16.2.2 Eliminating Other Sources of Ignition.
To prevent or eliminate sources of ignition, units shall: 1. Prohibit fuel personnel from wearing shoes that
have nails or other metal devices on the soles.
2. Advise fuel personnel not to carry or wear loose metal objects, such as knives or keys.
3. Check the exhaust piping on mobile refuelers daily to ensure that holes, cracks, or breaks do not exist.
4. Prohibit smoking, spark or flame producing items, open flames, or hot work within 50 feet of any refueling operation.
5. Defer all repair work on fueling equipment during fuel handling operations.
6. Avoid introducing lights (except approved safety lights for use in hazardous locations) into any compartment or space where fuel or flammable vapors may be present. (API has determined that ordinary commercial two- and three-cell flash- lights, using carbon zinc dry cell batteries, may be used safely around flammable fuel/air mixtures. Tests have proven them incapable of igniting vapors, even if accidentally dropped or the light bulb is crushed.)
Always assume that fuel vapors (in a tank or above a pool of fuel) are in the flammable range; i.e., proper fuel-air mixture to ignite. 7. Prohibit fuel personnel from carrying “strike
anywhere” matches or cigarette lighters around fuel systems/equipment.
8. Ensure that no repair or maintenance work is being conducted on the aircraft before starting the refueling or defueling operation.
9. Ensure that liquid oxygen (LOX) operations are not being performed and LOX handling equip- ment are not located within 50 feet of fuel operations.
10. Be certain that aircraft radar and all unnecessary radio equipment is switched off before refueling or defueling is begun. If it is necessary that equipment be warmed up prior to an immediate launch, be sure that it is not transmitting. The only exception to this rule occurs during hot refueling.
Hot refueling operations require the pilot to keep in radio contact with the tower at all times. 11. Prohibit aircraft fuel handling operations within
300 feet of ground radar equipment.
12. Equip all internal combustion engines operated within 50 feet of fuel handling operations with spark arresting type mufflers.
13. Do not start or stop any engine, regardless of its configuration, within 50 feet of a fueling or defueling operation. This prohibition includes aircraft being serviced and adjacent aircraft, as well as ground support equipment. The starting or stopping of an engine within 50 feet of a fueling or defueling operation is sufficient cause for the operator to immediately shut down the fuel pump. 14. Open valves slowly to avoid or minimize any
splashing in tanks.
15. Conduct open port/over-wing refueling only as a last resort and then only if operational necessity or aircraft design dictates.
16. Unless rapid turnaround of aircraft is required, hold hot refueling operations to the absolute minimum possible. Studies show that cold refuel- ing operations are inherently safer, are more cost-effective (less FARP operations), and are therefore preferred to hot refueling.
17. Ensure that personnel do not become entangled working in and around fuel handling equipment.
16.3 REDUCING OR CONTROLLING VAPOR GENERATION
In order to help prevent fires by reducing or controlling vapor generation, units shall:
1. Avoid handling aviation fuel in open containers. 2. Avoid refueling, defueling or draining aircraft, or
conducting fuel handling operations in a hangar or confined area, except for the removal of water and the extraction of samples from aircraft low point drains. This does not apply to structures specifi- cally designed for these operations.
3. Keep all fuel containers, such as aircraft fuel tanks or vessels, closed except when necessary to open for actual operation.
4. Avoid spilling fuel during fuel handling operations.
5. Take immediate action to clean up any spills that occur.
6. Properly dispose of oily waste or rags (in self-closing containers) immediately after using. 7. Never drive or move a refueler or defueler with a
leak in the tank, piping, or other equipment. 8. Report all leaks in any portion of the fuel systems
to the FO/FC.
9. Treat empty, or apparently empty, cans or contain- ers that formerly held aircraft fuels as though they still contain fuels. These containers still contain vapors and are dangerous until vapor-freed. 10. Be aware that fuel vapors are heavier than air and
will collect in low places such as sumps and berms.
11. Never dispose of waste fuel in other than approved containers or fuel-water separators.
12. Never top load or splash fill tanks. (This does not prohibit over-wing or open port refueling of aircraft that are configured for this operation.) 13. Keep all equipment and work areas neat, clean,
orderly, and in good mechanical condition. 14. Ensure that firefighting equipment and extin-
guishers are in good condition and readily avail- able to the maximum extent possible.
15. Never use fuel as a cleaning agent.
16. Unless specifically designed for and operational necessity dictates, fuel containers; e.g., drums, collapsible 500-gallon, which contain fuel, shall not be loaded internally to aircraft or ground vehicles unless designed specifically for that purpose.
16.4 EXTINGUISHING FIRES
All fuel handling personnel should be aware of the basic principles involved in extinguishing fires as well as the equipment used. Fuel handling personnel should also make certain that appropriate firefighting equip- ment as depicted by authorized allowances is in good
condition, and readily available whenever and wherever fuel handling operations are being conducted. For maximum effectiveness and safety, fire extinguishers must be operated in accordance with the specific procedures developed for each individual type. MIL- HDBK-844(AS) contains a special section on fire extinguishment, which has been extracted from NAVAIR 00-80R-14, U.S. Navy Firefighting and Rescue Manual. All refueling personnel should receive fire extinguishing training initially and annually (sus- tainment training) thereafter.
Use all fire extinguishers only for their intended purpose.
16.5 MINIMIZING HEALTH HAZARDS
Aviation fuels be handled with caution because of the obvious dangers associated with possible fires and/or explosions. Additionally, these materials, them- selves, present a danger to the health of fuel handling personnel. These dangers are as equally important as those of fires and explosions even though they are not so well-known. MIL-HDBK-844(AS) contains a de- tailed discussion of the health hazards of aviation fuels. In order to minimize the health dangers, fuel handling personnel shall:
1. Avoid entering enclosed areas where fuel vapors are present.
2. Keep to an absolute minimum the amount of time spent breathing fuel vapors. Good ventilation of work space is essential.
3. Stay on the windward, or upwind, side of spills when it is necessary to remain in an area where a large spill has occurred.
4. Stay on the windward, or upwind, side when conducting fuel handling operations, where the formation of vapors is unavoidable, such as at a truck fill stand.
5. Stop the fuel handling operation and move to a fresh air location immediately if a feeling of dizziness or nausea occurs.
6. Avoid skin contact with liquid fuels and tank water bottoms that can contain a high concentra- tion of FSII. If fuel or water bottoms do contact the skin, wash with soap and water immediately. 7. Never wash hands in fuel.
8. Dilute with water, then remove fuel-soaked clothing or shoes at once.
9. Wear eye protection and clothing that leaves a minimum amount of skin exposed during refuel- ing operations.
10. Use footwear that completely covers the feet in order to provide protection against fuel spills and fires. Shoes made of fabric or other absorbent materials are not acceptable.
16.6 CONFINED SPACES
Personnel entering or working in or around confined spaces exposed to fuels and fuel vapors will encounter potential hazards such as:
1. The lack of sufficient oxygen
2. The presence of flammable or explosive vapors 3. The presence of toxic vapors and materials.
These hazards may not always be readily apparent, detectable by odor, or visually obvious to persons entering or working within such spaces. Therefore, all confined or enclosed spaces such as fuel tanks and refueler/truck tanks will be ventilated and tested prior to entry. To minimize risk, fuelhandling personnel shall:
1. Never enter a tank or vessel that has contained any fuel until all safety precautions have been followed and then only with experienced, knowl- edgeable supervision present.
2. Use a blower-type mask or positive pressure hose mask, boots, and gloves if it is necessary to enter a confined area where fuel vapors may be present. More definite information regarding the hazards of confined spaces, hazardous environments, and gas-free engineering is contained in NAVSEA S6470-AA- SAF-010, U. S. Navy Gas-Free Engineering Program Technical Manual and the NAVOSH Program Manual 5100.23B. All personnel shall comply with the applica- ble policies and procedures specified in these manuals.