Aircraft Refuelling Procedure and

Precautions
1.1 Aircraft rule 25A prescribes the procedures of fuelling of aircraft. This part of
CAR gives
the procedures adopted for the fuelling of aviation fuel and similar products of an
aircraft.
These standard procedures are recommended to provide guidance to the aircraft
operators,
oil companies and other concerned authorities in order to minimize the hazards
arising out of
fuelling operations.
1.2 Much of this guidance will also apply to fuelling of aircraft and to cases of
maintenance of aircraft fuel systems. But supplementary instructions may generally
be
necessary to provide for specific cases.
2. DEFINITION
2.0 For the purpose of this CAR the following definitions shall apply.
2.1 Fuelling - shall mean dispensation of fuels and power boost fluids into an aircraft
for the
generation of engines power and augmentation of thrust, and shall include both
fuelling and
defuelling.
2.2 Fuelling Zone or Precautionary Area - is regarded as the area extending 6
metres
radially from the aircraft fuelling point, venting point and fuelling equipment.
3. GENERAL
3.1 No persons shall fill or replenish the fuel tanks of an aircraft from vehicles or
vessels
containing petroleum in bulk or from fuel hydrant installations except from vehicles
or
installations of a type approved by the Chief Inspector of Explosives or from barges
licenced
under the Petroleum Rule 1937. The fuel and other products delivered by the oil
companies

shall be of a quality already agreed to between the purchaser and the supplier but
shall
conform to approved specifications.
3.2 All the statutory rules regarding transportation, storage and handling of aviation
fuels and
similar products and for illumination of the fuelling zone as agreed by DGCA shall be
followed
by the concerned personnel.
3.3 No leaking or defective fuelling equipment shall be used.
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4. SUPERVISION OF FUELLING
4.1 The fuelling of an aircraft shall be done under the
supervision of a person nominated by operator or as
specified in the Quality Control Manual and shall be carried
out by authorised person from the oil company. The
Operator's representative shall ensure that the fuelling of
an aircraft is carried out in accordance with the prescribed
manner, following the conditions laid down by the aircraft
manufacturer. The approved personnel shall not move from
the place of fuelling leaving the aircraft and fuelling
vehicles unattended.
5. FUELLING CONDITIONS
5.1 The aircraft operator shall furnish written instructions to
the fuelling company regarding the correct procedure of
fuelling and precautions to be taken for particular types of
aircraft. These instructions shall include the fuelling
pressure, rate of delivery, etc. Special precautions, such
as in the case of switch refuelling (see 20) shall also be
intimated to the oil company in advance. All special
conditions and requirements of aircraft manufacturers during
their servicing and fuelling shall be followed by all
concerned.
6. FUELLING PLACE

6.1 The refuelling of an aircraft shall be done in an open place

so designated. As a general guide, the fuelling places
should be atleast 15 metres away from the nearest building
except those parts of building, which are constructed for
the purpose of direct loading/unloading of aircraft. The
aircraft shall not be fuelled within 30 metres of radar
equipment under test or in use in aircraft or ground
installations. The refuelling shall be carried out on a
level surface as far as possible. The nominated person
shall ensure that there is adequate restraint of the
aircraft by checking that the brakes are applied and the
wheel chocks are placed properly before the fuelling
operations are started.
7. APPROACH TO AN AIRCRAFT
7.1 While placing the refuelling equipment oblique approach to
the aircraft shall be followed. The equipment driven shall
be marshalled in position. Similarly withdrawal of
refuelling equipment shall be done under supervision. The
refuelling equipment shall never be reversed towards the
aircraft.
8. POSITIONING OF FUELLING EQUIPMENT
8.1 The refuelling equipment shall be placed in such a way that
a clear exit path is maintained all round the equipment to
CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
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and from the aircraft to allow its quick removal in case of
need.
8.1.1 In such cases when the fuelling vehicle is parked under
the aircraft, it shall be ensured that any accidental
spillage from the aircraft air vent does not fall on
the fuelling equipment.
8.2 The vehicles and equipments shall not be placed where they
may cause obstruction to the evacuation of persons from
occupied portions of the aircraft in case of an emergency.
9. MANNING OF FUELLING VEHICLES

9.1 Every refuelling vehicle shall be manned by atleast one

competent person. The operation of the vehicle shall be
done only by the competent person(s). Adequate manpower
shall be available to the competent person(s) in order to
shut off the flow of fuel and or manoeuvre/retreat the
equipment in case of an emergency.
10. FUEL QUANTITY DELIVERY
10.1 The exact quantity of fuel in terms of volume along with its
break up distribution in various tanks if desired shall be
detailed to the oil company representative. The oil company
representative shall issue a delivery receipt indicating the
quantity of fuel refuelled in the aircraft. The density of
fuel supplied shall be declared on this receipt, if so
desired.
11. APPROVAL OF FUEL SAMPLES AND STARTING OF FUELLING
11.1 Fuelling of an aircraft by the oil company shall be started
only after the fuel samples have been approved by the
aircraft operator and a clearance has been given to the oil
company to start the fuelling operations.
11.2 It shall be ensured that the fuel samples are free from
water and other contaminants. Fuel is to be checked by
approved water detecting device to ensure that it is free
from water.
12. SPECIAL PRECAUTIONS TO BE TAKEN IN THE FUELLING ZONE
12.1 Within Fuelling Zone, smoking, the use of naked lights or
operation of switches on lighting systems of other than
approved pattern shall be forbidden.
12.2 Unless fuelling takes place in a designated `No Smoking
Area', `No Smoking' signs shall be predominantly displayed
not more than 15 metres away from the fuelling equipment and
aircraft tank vents.
12.3 Persons engaged in fuelling operations shall not carry
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SERIES 'H', PART II 28TH APRIL, 1992

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matches or other means of ignition. They shall also not use
foot wear with exposed iron or steel studs, nails or lips.
12.4 Equipment with all metal wheels or rod capable or producing
sparks shall not be moved in the fuelling zone while
fuelling is in progress.
12.5 Aircraft borne auxiliary power units (APUs) which have an
exhaust influx discharging into the zone shall be started
before filler caps are removed or fuelling connections made.
12.6 No auxiliary power unit in the fuelling zone shall be
started in the fuelling zone when fuelling operation has
been commenced. If an APU has stopped for any reason, it
shall not be started when the fuelling is continuing and
there is a risk of fuel vapour ignition.
12.7 Ground Power Units (GPUs) whenever used shall be positioned
not less than 6 metres from the aircraft filling and venting
points and the fuelling equipment.
12.8 Only approved vehicles and equipment shall be run in the
fuelling zone. These vehicles and equipments shall be
subjected to regular inspection and maintenance to preserve
their safety characteristics (see also 17.1).
12.9 Exhaust of the refuelling vehicle shall not pass over the
fuelling hose intake hose.
13. SAFETY PRECAUTIONS AGAINST STATIC ELECTRICITY DISCHARGE
BONDING AND EARTHING
13.1 During fuelling, the prevention of fire risk due to static
electricity discharge is dependent upon efficient bonding
between the aircraft and the fuel supply source. Ideally,
earthing should be through apron earthing points designed
for this purpose. Dragchains and conductive tyres normally
accepted for earthing purposes are seldom effective under
all climatic conditions.
13.2 The aircraft, fueller,hose nozzle, filters, funnels or any
other appliance through which fuel passes shall be

electrically bonded throughout the fuelling operation.

Connection shall be made to designated points on clean and
unpainted metal surfaces of the aircraft and the fueller.
13.3 Before transfer of fuel commences, following procedures
shall be carried out in respect of bonding the fueller and
the aircraft.
13.3.1 Whenever apron earthing points exist the aircraft and
fuelling equipment shall be earthed to them.
13.3.2 The aircraft shall be effectively bonded to the
fuelling equipment.
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13.3.3 Whenever wing fuelling is employed, the nozzle of the
hose shall be bonded to the aircraft structure before
filler cap is removed.
13.3.4 In case of pressure fuelling, metal to metal contact
between the aircraft filling and the fuelling hose
coupling shall be ensured. In addition a bonding pin
or clip from the fuelling hose coupling to the aircraft
structure near the fuel receptacle may be used to
provide additional safeguard.
13.3.5 When refuelling from drums, barrels or similar
equipment is carried out, similar precautions shall be
taken to bond the pumping equipment, hose nozzle and
fuel container.
13.3.6 Whenever funnels are used, they shall be bonded both to
the nozzle of the hose or can and to the aircraft. If
a chamois leather is used, the metal ring around the
leather shall be bonded to the funnel.
13.4 The fuel valve shall not be opened before bonding
connections are made. Similarly, at the end of the fuelling
operations, first the fuel valve shall be closed, fuelling
coupling disconnected or the fuelling nozzle removed as the
case may be and then only shall the bonding connections be
broken.

13.5 All cables, clips and plugs used for bonding or earthing
shall be maintained in proper condition and regularly tested
for electrical continuity and a record thereof maintained.
14. SAFETY PRECAUTIONS AGAINST FIRE HAZARD
14.1 When any part of undercarriage assembly has become
abnormally heated during landing or taxying, the aircraft
shall not be fuelled until heat has dissipated. Fuelling
equipment shall not be positioned until the Operator's
representative has satisfied himself that there is no risk
from heated components.
14.1.1 In checking for high temperatures, care shall be taken
in approaching the wheels. The wheels shall be
approached from the fore or aft and never from the
sides.
14.2 Fire extinguishers of adequate capacity and approved type
shall be readily available before the transfer of fuel
begins. The straps securing them to the refuelling
equipment shall be unfastened before the fuelling operations
are started. Adequate number of trained persons shall be
readily available to operate these units.
14.3 The fire extinguishers shall be maintained to the standards
CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
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Rev. 1, 15th October, 2001 6
recommended by their manufacturers.
14.4 Fuelling crew shall be instructed in the procedure for summoning the
aerodrome fire
service.
14.5 Fuelling operation shall cease when a turbo prop jet aircraft manoeuvres so as
to
bring the rear jet outlets within 43 metres of the fuelling equipment or the aircraft
fuelling point
and vent system (see also 16.1).
15. SAFETY FROM ELECTRICAL STORMS/HEAVY RAIN
15.1 Extreme care shall be exercised while fuelling during electrical storms. Fuelling

shall
be suspended during severe lightning disturbances in the vicinity of the aerodrome
or
helipad.
15.2 Overwing fuelling shall not be carried out during electrical storms. Fuelling
shall be
suspended during heavy storm/rain.
16. HAZARDS FROM ADJACENT AIRCRAFT OPERATION
16.1 Before and during fuelling, it shall be ensured that no hazard arises to the
personnel or
equipment from the efflux from other aircraft or APUs. If the hazardous conditions
exist,
fuelling operation shall immediately by suspended until conditions permit
resumption of
fuelling operations (see also 14.5).
NOTE: It may be noted that the engine efflux of modern jet aircraft when taxying
could have
speeds up to 65 knots and a temperature above 50 degree Celsius even at a
distance of
30 metres from the exhaust point. This temperature may not be dangerous from the
fire point
of view, but the personnel and the equipment could be effected.
17. MAINTENANCE OF REFUELLING VEHICLE AND EQUIPMENT USED
17.1 All vehicles, their engines and equipment shall be subject to regular inspection
and
maintenance to preserve their safety characteristics. The engine, the electrical and
exhaust systems of such vehicles shall not make any sparks or flames. Vehicles
moving in
the danger zone shall be fitted with spark arrestors and flame traps.
18. USE OF PHOTOGRAPHIC FLASH EQUIPMENT
18.1 No photographic flash bulbs and electronic flash equipments shall be permitted
to be
used within 6 metres filling or venting points of an aircraft or fuelling equipment.
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19. OPERATION OF RADAR

19.1 Aircraft shall not be fuelled within 30 metres of radar
equipment under test or in use in aircraft or ground
installations.
20. SPECIFIC PRECAUTIONS IN CASE OF FUEL MIXTURES
20.1 Mixture of wide cut and kerosene turbine fuels could result
in the air fuel mixture in the tank being in the combustible
range at common ambient temperatures during fueling. The
risk of this type of sparking would be minimum if antistatic
additive is present in fuel.
20.2 In cases of fuel mixtures a reduced rate of fuelling shall
be adopted. The amount of reduction in flow rate needed is
dependent upon the fuelling equipment in use and the type of
filtration employed on the aircraft fuelling distribution
system (see also 5.1).
21. SERVICING AND MAINTENANCE OF AIRCRAFT DURING FUELLING
21.1 While fuelling is in progress, servicing, maintenance test
and repair activities shall be carried out subject to the
conditions stipulated in 21.1 to 21.12. Aircraft or other
maintenance work which may create a source of ignition
shall not be carried out while fuelling is in progress.
21.2 All ground equipment, such as platform steps shall be clear
of the aircraft. Because after fuelling, the aircraft has a
tendency to settle down due to increase in weight and this
changed attitude of the aircraft may thus cause damage to
the aircraft/such equipment.
21.3 The main engines of the aircraft shall not be operated.
Operation of APUs & GPUs shall be in accordance with the
provisions of 12.6, 12.7 and 12.8.
21.4 Only those switches which are essential in carrying out the
fuelling or servicing operation shall be operated when
fuelling in progress.
21.5 Strobe lighting which is likely to give spark shall not be
operated.

21.6 All connections between the ground equipment and the

aircraft shall be made before the filler caps are removed
and shall not be broken until the fuelling ceases.
21.7 In case of the use of battery trolleys, the electrical
circuit shall remain unbroken till the fuelling operation is
completed.
21.8 Vehicles operating in the fuelling zone shall not pass under
or park near the aircraft unless specifically required to do
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so for maintenance or fuelling purposes.
21.9 Aircraft combustion heaters shall not be used.
21.10 Only checking and limited maintenance work such as the
exchange of units shall be carried out on radio, radar and
electrical equipment. Testing of such equipments shall be
deferred until the fuelling is completed.
21.11 Radio equipment of approved types installed on fuelling and
servicing equipment may be operated.
21.12 All hand torches and inspection lamps and their cable
connections used in the fuelling zone shall be of explosion
proof/intrinsically safe type.
21.13 Only authorized persons and vehicles shall be permitted
within the fuelling zone and their number shall be kept to
the minimum.
22. FUELLING WITH PASSENGERS ABOARD AND DURING EMBARKATION AND
DISEMBARKATION
22.1 To reduce transit time and for security reasons, sometimes
airlines allow passengers to embark and disembark or remain
on board during fuelling operations.
22.2 In case wide cut turbine fuels are involved and/or the fuel
does not contain anti-static additive, it is advisable to
disembark the passengers before fuelling.

22.3 The decision to allow passengers to embark, disembark or

remain on board during fuelling is the responsibility of the
airline and following precautions shall be exercised by the
airline concerned:
a) Fixed wing aircraft with a seating capacity of less
than 20 shall not be permitted to be refuelled with
passengers on board.
b) Passengers are warned that fuelling will take place and
that they shall not smoke, operate switches or
otherwise produce sources of ignition.
c) The `No Smoking' and `Exit' signs are illuminated.
d) Provision is made for safe evacuation of passengers
via atleast two of the main passenger embarkation and
disembarkation doors in the event of the emergency. A
responsible person should be positioned at each door in
order to supervise evacuation of passengers, if needed.
e) If during fuelling, the presence of fuel vapour is
detected in the aircraft interior, or any other hazard
arises, fuelling should be stopped.
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f) Ground servicing activities and work within the
aircraft should be conducted in such a manner that they
do not create a hazard or obstruct exits.
g) Access to and egress from the areas where aircraft
escape chutes may be deployed should be kept clean.
h) When passengers are embarking or disembarking during
fuelling, their route should avoid areas where fuel
vapours are likely to be present and be under the
supervision of an airline official. `No smoking' should
be enforced strictly during such passenger movements.
23. FUEL SPILLAGE
23.1 In the case of a spillage covering an area greater than 5
square metres, fuelling operations shall stop. All persons
shall be evacuated from the effected area to a place at
least 15 metres from the spillage. Movement of persons and
vehicles in the affected area shall be avoided. It shall be

ensured that all activities are restricted to reduce the

risk of ignition.
23.2 Engines of vehicles within 6 metres of a spillage shall not
be started until the area is declared safe.
23.3 Prior to recommencing fuelling, action must be taken to
clean the spilled fuel. Fuel must not be washed into sewers
or drains.
24. HELICOPTERS
24.1 Because of design features of helicopters namely close
proximity of fuel intake and tanks to the passenger
compartments, it is recommended that passengers should not
be allowed to remain in the aircraft and be away from the
fuelling zone when fuelling is in progress. Engines should
not be operated when fuelling is in progress.
25. TRAINING
25.1 It is essential that all personnel connected with the
fuelling operations are adequately trained by their
employers and are supplied with appropriate instructions and
guidance on safe operating procedures. All such personnel
shall be fully conversant with the operation of fire
fighting equipment provided for the fuelling operations.