Api Ip RP 1597-2006
Api Ip RP 1597-2006
Api Ip RP 1597-2006
First edition
December 2006
First edition
December 2006
Published jointly by
API
and
ENERGY INSTITUTE, LONDON
The Energy Institute is a professional membership body incorporated by Royal Charter 2003
Registered charity number 1097899
The Energy Institute gratefully acknowledges the financial contributions towards the scientific and
technical programme from the following companies:
No part of this book may be reproduced by any means, or transmitted or translated into a machine language without
the written permission of the publisher.
The information contained in this publication is provided as guidance only and while every reasonable care has been
taken to ensure the accuracy of its contents, the Energy Institute cannot accept any responsibility for any action taken,
or not taken, on the basis of this information. The Energy Institute shall not be liable to any person for any loss or
damage which may arise from the use of any of the information contained in any of its publications.
The above disclaimer is not intended to restrict or exclude liability for death or personal injury caused by own
negligence.
Further copies can be obtained from Portland Customer Services, Commerce Way,
Whitehall Industrial Estate, Colchester CO2 8HP, UK. Tel: +44 (0) 1206 796 351
email: [email protected]
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Reasons for a misfuelling prevention program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
v
vi
FOREWORD
This Recommended Practice has been prepared jointly by the API Aviation Technical Services Sub-committee and
EI Aviation Committee, and is intended to provide guidance on the prevention of aircraft misfuelling.
This publication is intended to provide recommendations for safe practice, rather than rigid guidelines. Users
of this publication shall be aware that due consideration shall be given to the effect of any unusual or abnormal
circumstance, on which it is not possible to generalize within the scope of this publication. Specialist advice shall
be sought in these cases.
The guidance contained in this publication is primarily intended for overwing fuelling operations of civil
aircraft.
In addition, in some areas local or national statutory regulations also apply. This publication is intended to be
complementary to these established controls and practices.
The API/EI is not undertaking to meet the duties of employers to warn and equip their employees, and others
exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local and
regional laws and regulations.
Nothing contained in any API/EI publication is to be construed as granting any right, by implication or
otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither
shall anything contained in the publication be construed as insuring anyone against liability for infringement of
letters patent.
This publication is intended to assist those involved in overwing fuelling of civil aircraft to ensure the correct
fuel grade is delivered. Every effort has been made by the American Petroleum Institute and the Energy Institute
to assure the accuracy and reliability of the data contained in this publication; however, API make no representation,
warranty, or guarantee in connection with this publication and hereby expressly disclaim any liability or
responsibility for loss or damage resulting from its use or for the violation of any local or regional laws or
regulations with which this publication may conflict.
Suggested revisions are invited and shall be submitted to the director of standards, API, 1220 L Street, N.W.,
Washington, D.C. 20005 or The Energy Institute, 61 New Cavendish Street, London, W1G 7AR.
vii
ACKNOWLEDGEMENTS
The preparation of this publication was undertaken by Mr J. Thurston (Air BP) and Mr M. Tippl (ExxonMobil Fuels
Marketing Company), with input from technical representatives of the following companies:
Air BP Limited
Air TOTAL
Aviation Fuel Services GmbH
Chevron
ConocoPhillips
ENI
ExxonMobil Aviation International Ltd.
ExxonMobil Fuels Marketing Company
Kuwait Petroleum International Aviation Company Ltd.
Marathon Petroleum Company LLC
Shell Aviation Ltd.
Shell Oil Products US.
viii
1
GENERAL
1
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
2
2
2.1 SUMMARY Any orders received without specifying the grade, e.g.
where a pilot places an order for "200 US Gallons/litres
Refuelling staff shall obtain verbal confirmation of the a side" or "fill it up", shall be clarified to confirm the
fuel grade from the pilot for all overwing fuellings. In grade required and then repeated back to the customer
certain situations (sections 2.3 to 2.5), written for confirmation.
confirmation is required. Under no circumstances shall Orders for overwing fuellings can be received
refuelling staff assume what grade of fuel is required. verbally (personally or by telephone) only when the
Instructions to or between refuelling staff relating to refuelling is completed immediately following. All
overwing fuelling shall always include a reference to other instances shall require the order to be recorded
the grade of fuel required. This shall apply at all stages: after verbally being received from the pilot.
receipt of orders, transferring orders onto notice boards Refuelling staff shall not attempt to fuel an aircraft
and in all verbal communications. Overwing nozzles purely on their knowledge of the aircraft type. For such
shall be colour-coded; black for jet fuel and red for a critical activity, all staff shall comply with the grade
avgas (see section 2.8). Jet nozzles shall be fitted with confirmation procedures and not assume the grade
selective spouts (see section 2.5). Where wing decals required.
are not present on the aircraft, the fuelling shall not
proceed unless a Fuel Order Form is completed by the 2.2.2 Written records
customer. For full details of these procedures, refer to
sections 2.2 to 2.10. All verbal orders shall be recorded, including grade,
quantity of fuel to be delivered into each aircraft fuel
tank and aircraft registration information. The only
2.2 GRADE CONFIRMATION exception is for verbal orders received on the apron with
the fuelling completed immediately following. The
2.2.1 Verbal orders recording of verbal orders and their transmission within
the refuelling and associated site staff is critical in
Orders received verbally shall be repeated back to the ensuring that the correct fuel grade and quantity are
customer for confirmation. However, in all delivered. The use of customer confirmation records
circumstances the grade of fuel required shall be (i.e. meter tickets and other documentation that are used
confirmed. The essential information is: routinely to initiate normal fuelling or billing processes)
shall not be confused with the use of the Fuel Order
— Fuel grade. Form. The Fuel Order Form is used only under certain
— Quantity of fuel to be delivered into each fuel tank. conditions (see section 2.4). The use of the Fuel Order
— Aircraft registration. Form shall be on an exception basis and not used
3
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
routinely so as to highlight the importance of this non- confirmation immediately prior to the fuelling. The
routine task in delivering the correct grade of fuel to the wing decals are colour-coded as are the overwing
aircraft. nozzles (section 2.8).
1 * CAUTION - Confusion can be caused by language differences. The local name for jet fuel in one country may be similar
to the name for avgas in another. e.g:
— Spain: The local name for jet kerosene can be “petroleo”- very similar to petrol as used for gasoline (more like avgas), in
many countries.
— Greece: Kerosene is called by a derivative of the word for benzene, which is usually associated with gasoline.
4
PROCEDURES AND EQUIPMENT
for civil aircraft for details on both fuelling nozzle spout place and returned after each use. It is
and aircraft filler port design requirements. recommended that the small jet nozzle spouts be
Grade selective nozzle spout dimensions are as signed out when used and their return recorded.
follows: — A Fuel Order Form is used to obtain written
confirmation of the grade of fuel required from the
— AVGAS - Maximum nozzle spout diameter is pilot.
50 mm or 1,97 inch.
5
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
— Wing decals shall be fitted. markings for dedicated aviation fuel manufacturing and
distribution facilities, airport storage and mobile
— All overwing jet fuel nozzles are equipped with the fuelling equipment) on all fuelling storage and handling
wide jet nozzle spout. equipment shall be applied to assist in grade
recognition. As a minimum the following shall be
— The customer shall be advised to notify the adhered to:
refuelling staff of any change in the standing order
requirement if the aircraft type or grade fuel — Aviation fuel dispensing vehicles
requirement changes.
The identifying product grade labels (see EI 1542)
— A delivery ticket with grade and quantity shall be shall be applied to the front, back, sides, and
left with the fuelled aircraft where unattended prominently displayed inside the driving
fuellings occur. This provides the customer with compartment. In addition the grade decals should
the opportunity to confirm the grade supplied prior be visible from each fuelling hose reel and fueller
to operating the aircraft after fuelling. bottom load adapter.
At locations where it is impractical to have the jet fuel — Stationary/curbside fuelling cabinets
wide nozzle spout fitted because of the high number of
aircraft unable to accept them (more than five overwing Fuelling cabinets, which cover piping, filters,
fuellings per shift requiring the small jet nozzle spout) pumps, valves and hose reels, should bear grade
then the following procedure shall be adopted: identification labels (see EI 1542). Labels for the
specific grade should be installed on all sides, tops,
— The smaller diameter jet nozzle spout shall be and inside main access doors to stationary fuelling
permanently fitted. equipment.
6
PROCEDURES AND EQUIPMENT
— Visual examination for dirt, water and correct address health and safety issues and any legally required
colour (blue for avgas 100LL; red for avgas 80; Personal Protective Equipment required when
green for avgas 100) for the specific grade of avgas performing such work.
and water (white to straw/pale yellow for jet fuel) New personnel shall be thoroughly trained in how
is carried out on all samples inspected from the to fuel overwing aircraft prior to being allowed to fuel
system. aircraft without direct supervision.
Existing personnel who are called upon to
The use of grade selective couplings shall be extended undertake overwing fuelling shall be similarly trained.
as far upstream as possible. This establishes a physical An employee training record for overwing fuelling shall
barrier to prevent the loading of the incorrect grade of be maintained for every employee which indicates:
product into fuelling vehicles or other product transfers.
Airport fuelling vehicles shall be loaded though grade (i) job task training has been given and the date of
selective nozzles to prevent the inadvertent loading of such training, and
the incorrect grade into a fuelling vehicle. (ii) the signature of the trainer, and
The use of grade selective unloading for road (iii) a "yes/no" assessment of whether the trainee
transport deliveries to airport fuel farms/depots should demonstrated satisfactory understanding of the
be considered where possible. Even where grade training, and
selective offloading nozzles are used the quality control (iv) the signature of the trainee.
check described in this section shall be followed.
EI 1542 also addresses fuel grade identification for Where necessary, training records for existing personnel
fuel handling facility/equipment requirements which shall also be established.
will assist in identifying the correct equipment when Follow-up job observation (with refresher training
transferring fuel into the site. if it is found to be necessary) shall be undertaken by
supervisory or training staff at a frequency determined
by the manager based on his assessment of on-going
2.10 FUELLING PROCEDURES/TRAINING operator performance.
The dates and results of these follow-up
It is essential that all personnel involved in overwing observations shall be recorded on the operator's training
fuelling understand the consequences of any lapse in record.
maintaining correct procedures. It is therefore essential Training aides such as posters or bulletins
that personnel are fully trained to undertake overwing describing the requirements contained in this
fuelling of aircraft to prevent misfuelling. Recommended Practice which can be located on
Local staff shall develop a written, risk assessed, wall/doors/bulletin boards are useful reminders to
Job Task (see Annex C for an example of a Job Task) refuelling staff of the need for vigilance in preventing
which contains a step by step procedure on how to misfuelling.
overwing fuel an aircraft. This Job Task shall also
7
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
8
ANNEX A
In addition to other measures adopted to reduce the risk To be used on aircraft fitted with engines approved to
of misfuelling general aviation aircraft, wing decals use avgas with no grade identification displayed:
have been designed to clearly indicate the proper fuel
type for use in the aircraft. The correct decal should be 12,0 cm / 4,72"
placed adjacent to all fuel filler ports on civil aircraft by
the pilot or aircraft owner such that it is clearly visible,
but does not interfere in any way with aircraft operation.
AVGAS
7,0 cm / 2,76"
ONLY
conforming to ASTM D 910 or Defense Standard 91-
90.
Decal #3 is for use on aircraft approved to use jet
fuel conforming to ASTM D 1655 or Defense
Standard 91-91.
A.2 DESIGN
AVGAS
7,0 cm / 2,76"
100 LL
may be acceptable; however, the colour scheme, i.e.
white text on a red background for avgas and white text
on a black background for jet fuel is mandatory.
Recommended font is Univers 45 Light and text size is
54 point.
9
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
A.2.3 Decal #3 A.3.4 Configuration
To be used on aircraft fitted with engines approved to A protective transfer sheet shall be applied to the
use jet fuel: marked side of the polyester film. The transfer sheet
shall be paper suitably treated with a low tack, pressure
12,0 cm / 4,72" sensitive adhesive on the surface in contact with the
face side of the decal. The adhesive backing shall be
JET
protected by a suitable liner, treated paper or other
7,0 cm / 2,76"
11
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
Fuel Requirements
Fuel Grade Quantity
Jet Fuel Litre
BLACK
Aviation Turbine Kerosene
USG
Avgas Litres
RED
Aviation Gasoline USG
Aircraft Pilot/Operator
Name Date
Signature Time
12
ANNEX C
PURPOSE
Essential precautionary procedures are required to prevent the incorrect grade of fuel being delivered to aircraft.
FREQUENCY
As required.
PERSONAL PROTECTIVE EQUIPMENT (The trainer should describe the PPE required for this task, why
it is needed and its correct use and maintenance)
Gloves, safety boots, safety glasses, protective uniform, hearing protection and bump cap.
13
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
14
ANNEX C
•
of fuel required 2. Confirmation, by the methods noted below, shall with grade
always be obtained from the pilot or representative lettering marked
of the airline/operator. Grade confirmation in white.
immediately prior to fuelling shall be achieved by
either: Avgas
•
Red background
– Sighting the aircraft’s grade decals with grade lettering
Walk around the aircraft and look carefully at each marked in white.
fuelling port to check to see if there is at least one
decal signifying the grade, before you get ready to Diesel aircraft engines:
refuel the aircraft.
Several companies are now
If a decal is present, check that it is the same grade producing aircraft engines that are
as in the refuelling vehicle to be used for the powered by jet fuel or diesel. These
refuelling. engines are being installed on
aircraft that typically had previously
Note: If the decal is different from the grade of fuel been fitted with engines that used
in the refuelling vehicle, STOP what you are doing avgas.
until the correct grade of fuel to be delivered is
confirmed with the pilot. Fill out a Near Miss These aircraft represent a serious
Report. risk of misfuelling by the delivery of
avgas to an engine designed for
– OR diesel fuel. Also, because these
aircraft were originally designed for
– If there is no grade decal, a Fuel Order Form shall use with avgas, most will have
be completed by, and then signed by, the pilot or filling orifices that are too small for
an airline representative. the normal 67 mm jet fuel nozzle.
15
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
16
ANNEX C
17
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
18
ANNEX C
19
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
20
ANNEX D
REFERENCES
Defense Standard 91-90 Gasoline, Aviation: Grade 80/87, 100/130 and 100/130 low Lead
Defense Standard 91-91 Turbine Fuel, Aviation "Kerosene Type", Jet A-1
EI Standard 1542 Identification markings for dedicated aviation fuel manufacturing and distribution facilities,
airport storage and mobile fuelling equipment
SAE Aerospace Standard AS 1852 Nozzles and ports - Gravity fuelling interface standard for civil aircraft
1
Available from General Aviation Manufacturers Association, 1400 K Street NW, Suite 801, Washington, DC 20005,
Telephone: +1 (202) 393-1500
21
PROCEDURES FOR OVERWING FUELLING TO ENSURE DELIVERY OF THE CORRECT FUEL GRADE TO AN AIRCRAFT
22
Global aviation fuel handling publications
The Energy Institute is the provider of the following portfolio of equipment standards and operational
recommended practices to facilitate the safe and efficient handling of aviation fuel, particularly at airports.
They are available for use internationally. The titles include those that were developed jointly with the API.
These are available through the EI from either www.energypublishing.org or Portland Customer Services
(t: +44 (0)1206 796 351). The two API titles can be obtained from www.global.ihs.com. For further information
on the EI aviation fuel handling portfolio please contact [email protected].
General
Filtration equipment
EI 1550 Handbook on equipment used for the maintenance and delivery of 1st 978 0 85293 574 3
clean aviation fuel
EI 1581 Specification and qualification procedures for aviation jet fuel filter/sepa- 5th 978 0 85293 575 0
rators
EI 1582 Specification for similarity for EI 1581 aviation jet fuel filter/separators 1st 978 0 85293 576 7
EI 1583 Laboratory tests and minimum performance levels for aviation fuel 5th 978 0 85293 527 9
filter monitors
EI 1590 Specifications and qualification procedures for aviation fuel microfilters 2nd 978 0 85293 577 4
EI 1596 Design and construction of aviation fuel filter vessels 1st 978 0 85293 578 1
EI 1599 Laboratory tests and minimum performance levels for aviation fuel 1st 978 0 85293 579 8
dirt defence filters
EI Research report Electrostatic discharges in 2-inch fuel filter monitors 1st 978 0 85293 388 6
EI Research report Electrostatic discharges in 2-inch aviation fuel filter monitors Phase 2: 1st 978 0 85293 408 1
Properties needed to control discharges
EI Research report Investigation into the effects of lubricity additives on the performance 1st 978 0 85293 395 4
of filter/water separators
API 1543 Documentation, monitoring and laboratory testing of aviation fuel 1st A154301
during shipment from refinery to airport
API 1595 Design, construction, operation, maintenance, and inspection of avia- 1st A159501
tion pre-airfield storage terminals