Section 5 - Refueling Jet Aircraft

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Egbert Goodwin
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Section 5 - Refueling Jet Aircraft 5.1 Introduction to Refueling Jet Aircraft The corporate world relies on sophisticated jet aircraft as time saving tools.

This module is designed to prepare and familiarize you with the correct procedures for refueling corporate or business jet aircraft.

1 Section 5 - Refueling Jet Aircraft 5.1 Introduction to Refueling Jet Aircraft The corporate world relies on sophisticated jet aircraft as time saving tools. This module focuses on the refueling of business jet aircraft. As a Line Service Specialist, you will spend a significant amount of your time refueling aircraft of all types. This module is designed to prepare and familiarize you with the correct procedures for refueling corporate or business jet aircraft. Refueling operations for jet aircraft can be more sophisticated than the typical turboprop aircraft, since many business jet aircraft utilize single point or pre s s u re re f u e l- ing systems. Ty p i c a l l y, jet aircraft carry larger amounts of fuel than piston and turboprop aircraft, which demands attention to fuel management. Consequently, many of these systems utilize complex fuel control panels to regulate the d i rection and flow of fuel into the various fuel tanks. 5.2 Jet Engine Design The term jet means to shoot out a stream of hot gas from a nozzle, which is exactly what a jet engine does. E s s e n t i a l l y, air enters the engine inlet and is pushed/pulled through a series of spinning turbine wheels (spinning at high velocity). As the air passes through each successive turbine wheel, the blades systematically comp ress the air and route it into the hot section of the engine, where the compressed air is mixed with fuel and ignited. This combination of compression and ignition of the fuel/air mixture forms a jet blast that propels the engine (and aircraft) forw a rd. Over the past two decades, jet engines have undergone a transformation, both in appearance, and in performance. Older jet engines which usually featured a narrow cowling design, are being phased out, and replaced by a new generation of turbo-fan engines. The turbo-fan engine is a larger (diameter) engine with a large intake fan at the front. This design makes the engine more fuel efficient and quieter than the early pure jet engines. Most jet and turbofan engines refueled in the United States utilize Jet-A (AVJET) or turbine fuel. Remember, Jet-A should be clear to straw in color. Use caution, verify that you have the cor rect fuel before delivering any product to the aircraft. 5.3 Auxiliary Power Units (APUs) Many jet aircraft utilize auxiliary power units, commonly referred to as APUs to provide electrical and/or pneumatic power for aircraft systems while on the ground. The majority of APUs found on jet aircraft are themselves, a small turbine or jet engine which also operates on jet fuel supplied from the aircraft s on-board fuel tanks. Typically, the APU will be located near the rear of the aircraft, and like their larger counterparts, APUs generate an exhaust blast. Since the APU is frequently used while on the ground, it may be operating while refueling operations are underway. Some important points to remember when working and/or conducting refueling operations around the airc r a f t s APU: The APU can be very loud and hearing protection is required when you are in the vicinity of the aircraft. Remember to keep yourself and all refueling equipment well clear of the APU exhaust. REFUELING JET AIRCRAFT 1

2 5.4 Single Point Refueling Many business jet aircraft utilize the single point refueling system, sometimes called pressure refueling. This refueling method is designed to deliver Jet Fuel (from the refueler) into the aircraft in a fully enclosed system which is operated under pressure. In comparison with overwing refueling, the single point underwing method is safer, more efficient, and reduces the risk of a fuel spill. All aircraft which refuel by single point will have over wing filler caps which can be used if the pressure system is inoperative. However, these caps should not be opened without first talking with the flight crew as there may be pressure in the fuel tanks. Inadvertently releasing this pressure could cause injury or damage. Remember, before any refueling operation, attach the bonding cable to the aircraft. Gloves should always be used during refueling operations. Also, check to be sure that your refueling vehicle is equipped with the required 20 B-C type fire extinguishers. If the refuelers at your location are equipped with precheck equipment such as deadman timers and brake interlocks with status lighting, then you should perform a standard vehicle pre-check prior to using any refueling nozzle. The vehicle pre-check should be done in accordance with refueler manufacturer and fuel supplier recommendations Single Point System Design (Refueling Ve h i c l e s ) Although many larger airline type aircraft (which may be used as corporate aircraft) utilize dual single points to allow greater flow during larger fuel loads, most business jets are equipped with a single (single point) refueling point. To connect the refueling vehicle to the aircraft, the refueler s single point nozzle must be attached to the aircraft s single point fitting. Both nozzle and aircraft attach point are compatible, and neither can be opened unless they have been properly mated. G e n e r a l l y, the re f u e l e r s single point nozzle will be supplied by a 2 to 3 hose to provide the most efficient volume of fuel flow. However, since the single point system is fully enclosed while attached, the system s operating pre s- s u re (which is operated by the refueler unit) is an important component of each refueling operation. All airc r a f t that have single point systems operate within a m a x i m u m allowable operating pre s s u re of 50 psi. This maximum operating pre s s u re must never be ex ceeded. S u b s t a n t i a l damage to the airc r a f t s fuel system, internal stru c t u re, fuel tanks and other components can occur if the system s maximum allowable pre s s u re is exceeded. If the refueling unit is not operating pro p e r l y, or if the operating pre s s u re is not within the normal operating range, you must immediately STOP the flow of fuel to the aircraft, and call your supervisor or maintenance personnel Single Point System Design ( A i rc r a f t ) Aircraft single point refueling systems may comprise one or more of the following features. Single Point Access Access to the single point is different for each type of jet aircraft. While some aircraft such as the Sabreliner may incorporate the fuel cap as part of the aircraft s exterior skin, others may position the single point access within a panel which may be located at any one of several places on the aircraft. In general, business aircraft locate the single point access in the vicinity of the wing root, either fore or aft, and either above or below the wing. However, in some cases the same type of aircraft may have different locations for the single point adapter based upon the model, series, or year of manufacture. For details of single point location for specific aircraft, please refer to the Aircraft Service Guide included with this program. Automatic Fuel Shutoff and Pre-check Systems An important component of many jet aircraft single point systems is the automatic fuel shutoff. This component is designed to terminate the flow of fuel into individual tanks or the entire aircraft when full. To ensure that the system is working pro p e r l y, the system features a pre-check, which enables the refueling personnel to verify proper operation of the automatic shut-off during refueling operations. REFUELING JET AIRCRAFT 2

Typically, the aircraft pre-check system is operated by a button or switch located on the aircraft fueling panel, or in some cases, near the single point access.

The pre-check switch must be activated (and in some cases held on ) until fuel stops flowing into the aircraft.

3 Typically, the aircraft pre-check system is operated by a button or switch located on the aircraft fueling panel, or in some cases, near the single point access. To operate the pre-check, refueling must be underway and fuel must be flowing within the normal pressure range. The pre-check switch must be activated (and in some cases held on ) until fuel stops flowing into the aircraft. When the fuel stops flowing, this is verification that the automatic fuel shutoff system is operating properly. Releasing the switch (or returning it to the normal fueling position) will reactivate the flow of fuel into the aircraft. For those aircraft equipped with pre-check systems, the approved procedures must be completed at the commencement of every single point refueling operation. Fuel Control Panels Many single point aircraft incorporate a fuel control panel into the system to allow precise control and management of fuel that is being loaded into the various tanks within the aircraft. Although most are configured differently, typically, the fuel control panel will incorporate a master fuel system (power) switch, tank valve (on and off) switches, refuel/defuel switches, and fuel tank configuration diagram. In some cases, the single point hookup may be located inside the fuel control panel. The panel may also include fuel quantity gauges delivering a specific amount of fuel to the aircraft. These gauges may be calibrated in pounds rather than gallons. For fuel weight conversion applications utilize the conversion chart located at the end of Section 4. Fuel Vent Systems Since the basis of the single point refueling system is to deliver fuel under pressure, the aircraft s fuel vent system plays an important role in the operation of the aircraft s fuel system. Essentially, the aircraft must be able to constantly vent the air that is displaced as the fuel enters the aircraft tank(s). Therefore, this venting process is critical to ensure that over pressurization of the internal plumbing and tanks does not occur. Typically, aircraft vents are located on the outboard, underside sections of the wings, near the wingtips. When refueling certain business aircraft which utilize the single point system, you must always check the aircraft s fuel vents immediately after commencement of refueling, to ensure that fuel system venting is occurring. Verification is easily accomplished by confirming that air is being released out of each aircraft fuel vent. On some aircraft, prior to commencement of refueling operations, pressure within the fuel system must be released before refueling can begin. In addition, in the event that the fuel shutoff system has failed or if a shutoff valve has not closed properly, the fuel vents are also designed to route excess fuel overboard and relieve pressure within the system once the tank(s) have reached their maximum capacity. Be prepared to shut off the flow of fuel immediately if fuel is pumped overboard. Each fuel spill, no mater how small, must be cleaned up in accordance with all local and federal guidelines. Personal protective equipment must also be utilized Jet Aircraft Refueling Pro c e d u re s The following is the step by step procedure which must be followed when refueling a jet aircraft: 1) Understanding the service order Read the service order carefully, or if you receive a fuel order via radio; always write down the information and read back the order to verify the request. REFUELING JET AIRCRAFT 3

2) Use the proper refueler Select the proper refueler for the job and perform a walk around. Be certain that the unit is fully equipped and is ready for use.

4 2) Use the proper refueler Select the proper refueler for the job and perform a walk around. Be certain that the unit is fully equipped and is ready for use. Check the product tank for proper fuel, and to verify that you have enough fuel in the cargo tank. 3) Positioning the refueler Carefully drive the refueler into position in front of the aircraft, and verify that the aircraft has been secured with chocks. Maintain ten feet (10 ) between the aircraft and the refueler. Stop and set the park brake ensure that the unit will not move. 4) Review the Service Order Are the services ordered appropriate for this type of aircraft? Does the aircraft tail number match the number listed on the service order card? Does this aircraft require Jet A? Is this a Jet refueler? Is the previous meter reading correct? Are there specific servicing instructions (number of gallons, tanks, etc.)? If you have any questions, Stop. Ask for clarification or assistance before proceeding. 5) Setting up to refuel Begin by bonding the aircraft. Attach the clip to a nonpainted metallic surface on the landing gear. Position the ladder (if required). Zero the meter. If refueling overwing, pull the fuel hose out far enough to reach the farthest tank to be refueled. If refueling single point, reel out enough hose so that you can handle the nozzle easily. (If you have any questions, refer to the information provided on the service order card). 6) Refueling the aircraft (overwing) Always touch the nozzle to the filler cap to equalize the static prior to opening the filler cap. Always utilize wing protection mats when refueling over the wing. Open the filler cap on the aircraft and place it on the mat adjacent to the opening. Keep the nozzle in contact with the filler opening throughout the refueling operation. Use caution when inserting the fuel nozzle into the filler port; the nozzle should never be inserted more than three inches (3 ) into any fuel tank. Damage can occur to delicate equipment and rubberized bladders which seal the tank. While refueling, do not allow any contaminants such as dust, dirt, or water, into the tank. You should hold the nozzle and hose with both hands to avoid damage to the leading edge or deicing boots. Caution should be used to prevent pens, glasses, flashlights, service orders, or other objects from dropping into the tank. Fill all the tanks according to the directions indicated by the pilot on the service order card. Spilled fuel should be wiped up immediately (and appropriate gloves should be used during clean-up). When each tank is completed, the fuel cap should be replaced immediately before going to the next tank. Never leave an open fuel tank unattended. When refueling is completed, stow the fuel mat, and rewind the hose. Stow the nozzle properly to prevent the accumulation of water and dirt including the replacement of the dust caps. Never lay the nozzle on the ground. 7) Refueling the aircraft (single point) Bond the refueler to the aircraft. Reel out enough hose to handle the hose and nozzle easily. Open the fuel panel access door on the aircraft and remove the single point receptacle adapter cap. Grasp the truck s single point nozzle (coupler) by the handles, and position it against the aircraft filler. Rotate the handles to the right, clockwise, until it couples with the aircraft and locks securely into place against the stops. Engage the deadman control and begin the flow of fuel. Activate any test or automatic-shut off switches as re q u i red for the aircraft. Before continuous re f u e l i n g resumes, verify that all aircraft automatic shut off systems are operating corre c t l y. If the systems are not operating pro p e r l y, stop and check with your superv i s o r. Refuel the aircraft as requested. If required, verify that fuel is properly venting from the aircraft s fuel vents. Closely monitor all fuel gauges, switches, and/or tank status lights to verify that the fuel load is properly delivered. Close each applicable tank valve as the required fuel level is reached in each tank. Once the entire fuel load has been delivered, release REFUELING JET AIRCRAFT 4

the deadman control and close the flow valve on the fuel nozzle. Verify that all tank valves have been returned to their closed, off, or normal flight positions.

Disconnect the single point nozzle, and replace the receptacle adapter cap. Close all fuel access doors and double check that all latches and the door(s) are properly secured.

5 the deadman control and close the flow valve on the fuel nozzle. Verify that all tank valves have been returned to their closed, off, or normal flight positions. Double check each fuel quantity gauge to verify that the proper fuel load and distribution has been met. Turn the fuel panel switch to off. Disconnect the single point nozzle, and replace the receptacle adapter cap. Close all fuel access doors and double check that all latches and the door(s) are properly secured. Return to the refueler while holding the single point nozzle. Rewind the nozzle. DO NOT lay it on the ground or drag the fuel nozzle at any time. Replace the dust cover on the nozzle and secure it on the vehicle. Rewind/replace the deadman control. 8) Checking the Oil Ty p i c a l l y, on turbine aircraft the pilot will assist or s u p e rvise the checking of the oil. If the pilot has requested that you check the oil level, locate the oil access door in the cowling. Open the door and locate the dipstick. (On some aircraft, the location of the dipstick is diff e rent from the filler location). On jet airc r a f t the oil level may be identified by a filler sight gauge. Pull out the dipstick, wipe it clean, re - i n s e rt it, and pull it out again to determine the oil level. Repeat the p rocess a second time to ensure accuracy. If the oil filler location is diff e rent than the dipstick, replace the dips t i c k. Add the correct type and amount needed to bring the oil to the level ord e red by the pilot. Be careful to avoid spillage. Thoroughly wipe up any spilled oil immediatel y. Check the dipstick a final time to ensure that you have added the correct amount. Verify that the oil filler cap and dipstick are properly secured. Be absolutely certain that you have not left anything inside the cowling. Close the cowling access and check to be certain that it is secure. 9) Clean the windshield Clean the windshield carefully as discussed in Module 2, Safety. Use a lot of cleaning solution to hold dust and dirt in suspension. Always rub in the direction of the airf l o w. The job is complete when all of the dirt has been removed, and the windshield is clear of any cleaning solution. 10) Stow and check Stow the ladder. Remove the bonding cable from the aircraft, and carefully rewind it onto the reel. 11) Complete the paperwork Check the meter for the ending reading. Complete the paperwork according to the pro c e d u res outlined p re v i o u s l y. 12) Perform a final visual check Prior to leaving the area, DOUBLE CHECK to ensure that all panel doors on the aircraft are properly closed. Verify that the refueling equipment, including ladders, the deadman unit, refuel hose(s), and bonding cables have been removed or disconnected from the airc r a f t and are properly stowed on the refueling vehicle. 5.5 Jet Airc r a f t The following Jet Aircraft are included in the accompanying video: Manufacturer Beech Aircraft (Raytheon) Canadair (Bombardier) Cessna Models Beechjet 400A Canadair Challenger All Models Citation, Citation I, II, III, V/Ultra, VI, VII, X Dassault Falcon 10/100, 20/200, 50, 900, 2000 Gulfstream G-II, G-III, G-IV, G-V Hawker (Raytheon) HS , 600, 700, 800, 1000 Israel Aircraft 1123 Westwind, 1124, Westwind II, Astra Learjet Learjet 24/25 Series, 35/36 (Bombardier) Series, 55, 31, 60 REFUELING JET AIRCRAFT 5

6 Manufacturer Models Lockheed Jetstar Dash 6, Dash 8, Jetstar II Sabreliner All Models 5.6 Close As discussed previously, always make an effort to avoid spilling fuel. Spilled fuel should be cleaned up immediately using the appropriate procedures and protective gloves and equipment. Upon completion of all jet refueling operations, rewind the hose using caution to never drag the nozzle or lay it on the ground. Stow the nozzle properly and replace dust covers to prevent the accumulation of dirt. REFUELING JET AIRCRAFT 6

727 Fuel System. Fuel is stored in both wing and a center tank. Total fuel capacity is 767 gallons or 50,800 pounds.

727 Fuel System. Fuel is stored in both wing and a center tank. Total fuel capacity is 767 gallons or 50,800 pounds. 727 Fuel System General Fuel is stored in both wing and a center tank. Total fuel capacity is 767 gallons or 50,800 pounds. U.S. gallons Pounds L/M. 1793 11,500 R/M. 1793 11,500 Center 4086 27,800 Maximum