GOVERNMENT OF INDIA CIVIL AVIATION REQUIREMENTS
CIVIL AVIATION DEPARTMENT SECTION 2 - AIRWORTHINESS
SERIES 'H ' PART III
ISSUE I, DATED 27TH AUGUST '1992
FILE NO. 11-690/92-AI(2) EFFECTIVE : FORTHWITH
Subject :Aviation Fuel at Airport : Storage, Handling and
Quality Control.
1. APPLICABILITY:
Aircraft Rule 133(B) empowers Director General of Civil
Aviation to approve organisations engaged in storage,
compounding, blending of aviation fuels, lubricants and
products including fuelling/de-fuelling of aircraft.
Further CAR Series E, Part IV specifies the general
requirements for approval of organisation engaged in
blending, storage and distribution of aviation fuel in bulk,
lubricants and special petroleum products. All fuel vendors
must have their installations/terminals approved by DGCA in
terms of the above CAR.
This part of the CAR lays down the minimum requirements that
fuel vendors must comply and they may be summarised as
ensuring that
i) Proper quality control and fuelling procedures are
adhered to
ii) Sampling tests of fuel and inspections of installations
are correctly completed and records kept.
2. SCOPE:
Reference is made in this part of the CAR to the recording
of deliveries of fuel, their sampling and testing and
maintenance and cleaning of installations. The records
should be drawn up, signed and dated by the person accepting
deliveries into or dispensing fuel from the AVIATION FUEL
STATION (AFS), carrying out the fuel checks, maintenance or
cleaning operations immediately after completion of work.
It is for the fuel vendors to decide the form the records
should take, but it is essential that they are kept in an
orderly fashion and in such a way as to maintain their
legibility. The records/forms the vendors adopt must be
reflected in their Quality Control Manual.
It is responsibility of fuel vendor who has the management
of an AFS at an airport to satisfy himself on delivery of
fuel into the installation that the fuel is of a grade
appropriate to the installation to which it is being
delivered, that the installation is capable of storing &
dispensing the fuel in a state fit for use in aircraft, that
the installation is correctly marked to show the grade, or
grades of fuel it contains and that the fuel being delivered
has been sampled and tested to ensure that it is in a fit
state for use in aircraft. He shall also satisfy himself by
sampling & testing that the fuel is fit for use before it is
delivered into an aircraft. He is required to keep written
records of the dates, quantities and grade of all
deliveries, details of sample taken and the results of test
and details of maintenance and cleaning of the installation.
All procedure so adopted must be documented in the fuel
vendors Quality Control Manual and got approved by DGCA.
When the operator of an aircraft requests, the manager of an
installation should provide him with a written statement of
the quantity and type of fuel supplied.
PART - I
RECEIVING BULK FUEL SUPPLIES
1 DOCUMENTATION:
1.1 When delivering aviation fuel the suppliers will normally
present a company release note and delivery receipt
certificate which he will require to be endorsed by the
person in charge of the AFS or his representative to the
effect that the fuel is as ordered.
2. PRE-DELIVERY CHECK:
2.1 An aviation delivery vehicle shall be designed as per
approved specifications and internally cleaned yearly.
2.2 Before the release note and delivery receipt certificate is
completed and delivery accepted the person responsible for
receiving the fuel should
2.2.1 Examine the seals on the delivery vehicle and ensure
that they are intact.
2.2.2 Check that the grade and quantity as shown on the
certificate is as ordered, and corresponds with the
grade of fuel already in the receiving tank.
2.2.3 Carry out a water check on the fuel already in the
tanks(s) in accordance with the procedure in Part VIII
and if necessary flush the water drains until a clear
and water free sample is obtained.
2.2.4 Check that there is sufficient available capacity in
the receiving tank(s) for the quantity of fuel to be
received.
2.2.5 If a filtration system of 180 mesh or finer is not
fitted in the input to storage lines of the
installation, check that cone filters are in a position
on the delivery vehicle outlets.
2.2.6 Allow the delivery vehicle to stand on level ground for
ten minutes, draw a sample from the outlet tap of each
vehicle compartment from which fuel is to be delivered
and check in accordance with procedure in Part VIII.
2.2.7 If the sample is unsatisfactory, the procedure should
be repeated if a third sample is necessary and also
proves unsatisfactory, delivery of the fuel should be
refused.
2.2.8 If the sample is satisfactory, complete the appropriate
bonding procedure prior to delivery of the fuel into
the selected and correctly grade plate receiving point.
1.3 RECORDS:
Record the results of the pre-delivery inspection and sample
tests and details of the quantity and grade of fuel
delivered (into each tank if more than one).
PART - II
STORAGE OF FUELS IN BULK
1. SETTLING TIMES:
1.1 On completion of delivery and before any aviation fuel is
dispensed from the receiving tank, the fuel should be
allowed to settle for a period depending upon the type of
fuel and its depth in the tank, the type of tank and its
input filter arrangement, and the method by which fuel is
drawn from the tank.
1.2 For tanks fitted with floating suction devices for
dispensing fuel, the minimum settling times are one hour for
horizontal tanks and two hours for vertical tanks. The
periods are appropriate only when, in the case of AVGAS a
tank input filter of not less than 180 mesh gauze is fitted,
or in the case of aviation turbine fuels an input
microfilter, or a filter separator with a nominal 5 micron
rating for solid particles and 15 parts per million for
water, is fitted.
1.3 For tanks with floating suction devices and which do not
meet the filter criteria set out in paragraph 1.2, and for
all tanks with other dispensing systems, the minimum
settling times are half an hour per foot depth of fuel in
the tank in the case of AVGAS, and one hour per foot depth
for aviation turbine fuels.
1.4 No fuel should be dispensed from the receiving tank between
the beginning of the discharge from the delivery vehicle,
and the water and fuel cleanliness check made after the
appropriate settling time, and carried out in accordance
with the procedures in Part VIII.
2. TANKS:
2.1 Each airfield storage tank for JET A-1/JP-5/ATF K-60 shall
be internally epicoated and equipment with a floating
section.
2.2 All possible precautions should be taken to avoid the entry
of water and dirt into storage tanks. Open ended pipes,
hoses and sampling points should be fitted with dust caps,
plugs or other suitable protection, which should be replaced
tightly after use. With buried tanks, the manhole chamber
should always be kept clean and clear of water.
2.3 Provision should be made for withdrawing water from the
lowest points of tanks. With above ground tanks this should
be by means of a drain cock fitted at the lowest point, and
with buried tanks from the tank sump by means of a thief
pump.
2.4 The cause of any contaminated samples should be investigated
immediately, and an internal inspection and cleaning of
tanks carried out if frequent evidence of contamination is
found.
2.5 As a routine measure, tanks should be internally inspected
at least every three years, if inlet to the tank are fitted
with 5 micron filter elements and once in two years in case
tank are fitted with 10 micron filter element. With a newly
lined tank an inspection should be completed one year after
the lining was installed to check for soundness and
adherence to the tank shell. Any defects should be
rectified before the tank is refilled.
2.6 Floating sections shall be inspected once in a week for
satisfactory operation.
2.7 Tank bottom sample of ATF shall be tested for
microbiological growth once in a year.
3. FILTERS:
3.1 AVGAS installations: Tank input and output filters of not
less than 180 mesh gauze should be fitted. They should be
inspected weekly, cleaned if necessary and repaired or
replaced if damaged.
3.2 Aviation turbine fuel installations: Microfilters of 5
micron rating or filter separators should be fitted on input
lines, and a filter separator on the output side of the
pumps. The filter separators should conform with the
specifications in paragraph 1.2 above.
3.3 With both filter separators and micro filters, the pressure
differential should be checked weekly at the maximum
possible flow rate. The elements should be changed when the
pressure differential limit specified by the manufacturer is
reached.
3.4 Should any sudden and significant change from the previous
trend of recorded differential pressures occur, the elements
of microfilters and filter separators should be inspected to
ensure that they are functioning correctly. They should
also be inspected and if necessary replaced:
i) on significant reduction in rate of flow;
11) on continuing unsatisfactory drain samples.
As a matter of routine, the elements of filter separators
should be replaced after three years use.
4. LABELING AND COLOUR CODING:
4.1 All tanks should be labeled and colour coded to identify the
grade of fuel they contain. Pipelines should also be
similarly labeled and colour coded. The form and dimensions
of labeling and colour coding are illustrated in Figure 1.
The overall dimensions of the grade labels should not be
less than illustrated, but the dimensions of the coloured
segments of both labels and pipelines may be varies provided
that the primary indicator colours for the grades (Red for
AVGAS, and Black for Jet A-1) predominate. The grade
wording as illustrated should always be used.
4.2 As an additional measure to avoid refuelling errors it is
recommended that the appropriate grade markings or a band of
the appropriate primary grade indicator colour referred to
in 4.1 should be painted on delivery hoses or pipes as close
as practicable to the delivery nozzle, but not on the nozzle
itself. Any colour coding on the delivery nozzle should be
provided by a material which will not flake or separate from
the nozzle in general use, for example a securely attached
plastic sleeve or ring.
5. SAMPLING AND CHECKS:
5.1 Storage tanks should be constructed or modified so as to
allow upper, middle and lower samples to be taken. These
may be necessary from time to time for purposes of analysis.
5.2 Sampling in accordance with the procedures in part VIII
should be carried out after sample line flushing sufficient
to ensure that a tank bottom or sump sample is obtained:
i) each day before the first delivery from the tanks;
ii) immediately before receipt of fuel into the tanks;
iii) after receipt when the fuel has been allowed to settle
for the recommended period.
5.3 If a sample is unsatisfactory further samples should be
taken. Fuel should not be dispensed from the tank until a
satisfactory sample has been obtained.
6. PURGING:
6.1 Water should not be allowed to remain in aviation fuel
storage tanks. Any water found should be removed
immediately, and in the case of excessive water or sediment
steps should be taken to find and eliminate the source. In
addition, all filter separators, microfilters, gauze filters
and other drain points on static equipment or pipelines
should be purged once daily, and the drawn fuel checked in
accordance with the procedures in Part VIII. If
contamination is found, further samples should be drawn
until a clean sample is obtained.
6.2 When samples are found to be in good condition they can be
returned to storage to avoid waste of fuel. If
contaminated, they should not be returned to any part of the
aviation fuelling system unless contaminant(s) are
completely settled out and removed.
7. HOSE CLEANLINESS:
Fuel in delivery hoses should be recirculated if no fuel has
been dispensed from an installation for a period of two
days. If any fuel is left in hoses for a longer period than
this, it should not be recirculated or dispensed to
aircraft unless a sampling check in accordance with the
procedures in Part VIII shows it to be uncontaminated.
8. HOSE REQUIREMENTS:
8.1 Aviation delivery hoses shall conform to IS/BS/API
specifications.
8.2 Before commissioning a new hose, aviation product on which
it is going to be commissioned shall be stored in the hose
for a period of 24 hours with both ends blanked.
Subsequently a sample shall be taken of the product stored
in the hose and checked for discolouration. If the product
is found to be discoloured, the hose shall be emptied and
fresh product stored in it for a further period of 24 hours
and observation as observed made. This procedure shall be
repeated till the product from the new hose shows no
discolouration.
8.3 Alternately, 10,000 litres of the product shall be
circulated through a new hose and a sample taken at the end
of circulation shall show no disclouration.
8.4 If the fuelling equipment has not been used for 24 hours,
the hose shall be pressurized to the normal working pressure
and tested. Every morning the hoses shall be checked for
abrasion, soft spot, bulgings or any other damage.
9. FLOATING SUCTION CHECKS:
9.1 Float buoyancy should be checked atleast weekly.
9.2 At monthly intervals a test should be made of the
effectiveness of devices such as check wires fitted to the
system to prevent the suction head drawing fuel from the
tank bottom if the float should be punctured. Due to the
possibility of wearing of the links, the use of a chain to
restrain the suction head is not recommended.
10. LABORATORY TESTS OF FUEL STOCKS:
The quality of static bulk stocks of aviation fuels, that is
those which have not been added to during the last six
months for Jet A-1, AVGAS should be verified for full
specification test and re-tested every 3 months thereafter
by laboratory test before further issues are made. The fuel
supplying companies can provide information on DGCA approved
laboratories that can undertake these tests.
11. RECORDS:
Storage tanks should be cleaned once in a year. Records
should be kept of all deliveries into and from the
installation; the results of sampling, pressure
differential, filter and floating suction head checks;
purging of the system; tank inspection; and any
rectification of maintenance work carried out.
PART III
AIRCRAFT FUELLING VEHICLES
1. GENERAL:
1.1 Grade identification labels of the types illustrated in Part
II paragraph 4.1 should be carried in prominent positions on
fuelling vehicles, including at fuel inlets and outlets.
Delivery hoses/nozzles should also be colour coded in
accordance with Part II, paragraph 4.2.
1.2 Tanks, lined or unlined, should be kept clean and
precautions taken to prevent the entry of contaminants.
Open ended pipes, hoses and sampling points should be fitted
with dust caps, plugs or other suitable protection, which
should be replaced tightly after use.
1.3 Atleast every three years tanks should be internally
inspected for cleanliness. Lined tanks should be inspected
for lining defects. Any found should be repaired, or if the
defects are extensive, the lining replaced..
1.4 Each refueller tank shall be cleaned once a year.
2. SAMPLING AND PURGING:
2.1 As a routine measure, fuelling vehicles should be purged of
water and sediment once a day before use. This purging
should encompass all drain cocks, tank compartments, filter
separators, fuel monitors, microfilters, gauze filters and
air separators.
2.2 Samples of fuel should be taken and checked in accordance
with the procedures in Part VIII:
i) following each reload or top up of a fuelling vehicle;
ii) after the vehicle has been exposed to heavy rainfall,
sleet, thawing snow, or vehicle washing.
2.3 If the first sample is found to be contaminated, further
samples should be taken. If unsatisfactory samples continue
to be obtained, action should be taken to identify and
remove the cause. Until satisfactory samples are obtained
no deliveries from or into the vehicle should be made.
2.4 When samples are found to be in good condition they can be
returned to storage to avoid waste of fuel. If in
unsatisfactory condition, samples should be disposed of and
not returned to any part of the fuelling vehicle or aviation
fuelling system unless contaminant(s) have been completely
settled out and removed.
3. FILTERS:
3.1 Hose end protection filters of 100 mesh gauze should be
fitted. They should be inspected atleast monthly, and if
necessary cleaned, repaired or replaced. Excessive
contamination of a hose end filter may indicate
deterioration of the hose lining. The hose should be
replaced if this is confirmed.
3.2 Deliveries of AVGAS from the vehicle should be made through
a microfilter with a nominal rating of 5 microns.
3.3 Vehicles delivering aviation turbine fuels should be fitted
with a microfilter or a filter separator or monitor with a
nominal 5 micron rating for solid particles and 15 parts per
million for water.
3.4 Checks should be made at weekly intervals on the pressure
differentials at the maximum possible flow rate on
microfilters, filter separators or filter monitors
(whichever are applicable). Elements should be changed when
the differential reaches the limit recommended by the
manufacturer. Should any sudden and significant change from
the previous trend of recorded differential pressures occur,
the elements should also be inspected to ensure that they
are functioning correctly. They should also be inspected
and if necessary changed:
i) on significant reduction in flow rate;
ii) on continuing unsatisfactory drain samples.
As a matter of routine, the elements of filter separators
should be replaced after three years use, and the elements
of monitors after two years use.
3.5 The filtration system in refueller/dispenser shall be
subjected to milipore test by gravimetric method once in 3
months at all airfields.
4. HOSE CLEANLINESS:
4.1 Fuel in delivery hoses should be recirculated if no fuel has
been dispensed from a fuelling vehicle for a period of two
days. If any fuel is left in hoses for a longer period than
this it should not be recirculated or dispensed to aircraft
unless a sampling check in accordance with the procedures in
Part VIII shows it to be uncontaminated.
5. FUELLING VEHICLES USED FOR STORAGE:
The guidance given in this part in relation to fuelling
vehicles in equally applicable to vehicles or trailers used
for fuel storage, except that after delivery of fuel and
prior to the sampling that is referred to in paragraph 2.2
(i) a settling time of half an hour per foot depth of fuel
should be allowed in the case of AVGAS, and one hour per
foot depth for aviation turbine fuel.
6. RECORDS:
Records should be kept of all deliveries into and from
vehicles; the results of sampling, pressure differential and
filter checks; purging and tank inspections; and any
rectification or maintenance work carried out.
PART IV
HYDRANT SYSTEMS
1. HYDRANT PITS:
1.1 All pits should be grade marked and kept clean and free of
water. They should be checked atleast weekly and after
heavy rain or snow, and any contaminants removed. Monthly
checks should also be carried out to verify the correct
operation of shut-off valves and grade selection devices.
1.2 All valves and fittings should be checked weekly for leaks,
and rectification action taken as necessary.
2. WATER SAMPLING EXTRACTION PITS:
2.1 These should be checked for water atleast weekly. If water
is found it should be removed and the fuel sampled,
following the procedures set out in part VIII. No fuel
should be dispensed until an uncontaminated sample is
obtained.
2.2 The drain point should be checked weekly for leaks,
rectification action taken as necessary, and any waste fuel
in the pit removed.
3. SHOCK ALLEVIATORS:
Their condition should be checked at monthly intervals, and
the air pressure adjusted as necessary to conform with the
designed operating level. The gland of the isolating valve
should at the same time be checked for leaks and repaired or
replaced if defective.
4. DISPENSERS-SAMPLING,PURGING AND PRESSURE DIFFERENTIAL
CHECKS:
4.1 Hydrant dispensers, although not classed as bulk fuel
carriers, may nevertheless have dispensing systems which
fall into the same category as those on fuelling vehicles.
These systems should conform with the specifications and be
checked in accordance with the procedures set out in Part
III - AIRCRAFT FUELLING VEHICLES.
4.2 Checks should be made at weekly intervals on the pressure
differentials on microfilters, filter separators or filter
monitors (whichever are applicable), the elements of which
should be changed when the differential reaches the limit
recommended by the manufacturer. Should any sudden and
significant change from the previous trend of recorded
differential pressures occur, the elements should also be
inspected to ensure that they are functioning correctly.
They should also be inspected and if necessary changed:
i) on significant reduction in flow rate;
ii) on continuing unsatisfactory drain samples.
As a matter of routine, the elements of filter separators
should be replaced after three years use, and filter
monitors after two years use.
4.3 Immediately after fuelling is completed, a sample should be
drawn from the dispenser and checked in accordance with the
procedures set out in Part VIII. Ideally this sampling
check should be carried out before the aircraft leaves the
refuelling point, or if this is impracticable and radio
communication with the aircraft can be established quickly,
it should be completed and assessed before the aircraft is
positioned ready for take off.
4.4 If the sample is unsatisfactory a further sample should be
tested. If this is also unsatisfactory, the aircraft pilot
or operator's representative should be informed immediately
so that arrangements can be made to check the state of the
fuel in the aircraft tanks. Take off should not be
attempted until this has been done and the fuel found to be
free of contamination. No further fuellings should be made
from the system until the reason for the presence of
contaminant(s) has been established, and they have been
removed.
5. RECORDS:
A record should be kept of quantities of fuel dispensed, the
results of all checks and sampling, and any maintenance and
rectification action carried out.
PART V
BARRELED SUPPLIES
1. DELIVERY, HANDLING AND STORAGE:
1.1 Before accepting delivery from the fuel supplier, a check
should be made of the state of barrels and their seals.
Delivery should be refused of any leaking barrels or if
their seals are broken.
1.2 The number of barrels, grade markings, and fuel company
inspector's marks should be checked against the details in
the suppliers' release and consignment notes.
1.3 The barrels should be stored under cover, clear of the
ground and on their sides with the bungs in the 3 o'clock or
9 o'clock position.
1.4 A system of storage or a procedure should be followed which
will ensure that the oldest fuel in store is used first,
according to batch numbers and date of filling of the
barrels
1.5 To minimize the risk of fuelling errors, different grades of
fuel should be stored separately from each other.
2. SAMPLING:
Before fuel is decanted, or dispensed from barrels into
aircraft, it should be checked for contamination in
accordance with the procedures set out in Part VIII.
3. DECANTING AND DISPENSING:
3.1 Fuel should be decanted from barrels into fuelling vehicles
or storage preferably by means of a suitable pump and
through a microfilter or filter separator, though AVGAS may
alternatively be decanted through a funnel fitted with a 180
mesh (or 20 x 250 Hollander weave) gauze filter or a good
clean chamois leather. It is important to ensure that all
chalk deposits are removed from a new chamois leather before
use.
3.2 If fuel is to be dispensed from barrels into aircraft, the
barrels should be stood on end and the contents allowed to
settle for 10 minutes before the sampling check referred to
in paragraph 2 is completed. If satisfactory samples are
obtained the fuel should be dispensed through a suction
standpipe designed so that fuel cannot be drawn from a depth
lower than 3 inches from the barrel bottom. The bottom 3
inches of fuel should not be used in aircraft.
3.3 AVGAS should be dispensed direct into aircraft only through
a 180 mesh gauze or equivalent filter.
3.4 Delivery of aviation turbine fuel direct into aircraft tanks
should be made through a microfilter, or filter separator
with a nominal 5 micron rating for solid particles and 15
parts per million for water.
3.5 All equipment used in decanting or dispensing barrelled fuel
should be kept in a scrupulously clean condition.
3.6 After decanting or dispensing fuel, replace bungs tightly.
Any barrels still containing fuel that is to be used in
aircraft should be resealed.
3.7 Barrelled fuel - If, after the barrels have been filled by
the supplying company, the periods stated in the Table below
have been exceeded, barrelled fuel should not be used unless
it has been assessed as fit for use in aircraft by
laboratory tests.
AVGAS Six months
Aviation turbine fuels Six months
4. RECORDS:
Records should be kept of all barrelled deliveries,
decanting and dispensing of fuel, and sampling checks.
PART VI
DEFUELLING
1. GENERAL:
1.1 When an aircraft is to be defuelled instructions on the
disposal of the fuel should be obtained from the aircraft
operator. The manager of the aerodrome fuel installation
into which the fuel is drawn should not return it to
aircraft tanks if he has reason to believe that the fuel is
not fit for use in aircraft.
1.2 The acceptance of fuel from aircraft into fuelling vehicles
or aerodrome storage tanks can introduce two hazards to
quality:
i) water, other liquid or sediment in the aircraft tanks
may be introduced into the vehicle or storage tanks;
ii) fuel taken from aircraft tanks, and any resultant blend
with existing contents of the vehicle or storage tanks,
may not meet the appropriate product specification.
2. PROCEDURES:
2.1 To minimize the hazards referred to above, it is recommended
that aircraft should be defuelled into an empty fuelling
vehicle, or an empty storage tank segregated from other
parts of the installation, which has previously held the
grade to be defuelled. As an additional precaution, before
defuelling commences, samples should also be taken from the
drain cocks of each aircraft tank to be involved in the
operation, and checked in accordance with the procedures in
Part VIII.
2.2 The obtaining of unsatisfactory samples need not preclude
defuelling but will call for particular attention to be paid
to the thoroughness of the cleaning of the installation
after disposal of the defuelled product. It follows also
from paragraph 1.1 above that if unsatisfactory samples are
obtained the withdrawn fuel should not be returned to
aircraft tanks.
2.3 Irrespective of the results of this sampling, after disposal
of the fuel the defuelling vehicle or storage tanks and
systems used should be flushed to remove all traces of the
defuelled product before further use. Flushings should not
be returned to the aerodrome fuel installation or used in
aircraft.
3. RECORDS:
Records should be kept of all defuelling operations
including the registration of the aircraft involved, the
results of sampling checks, the quantity and grade of fuel
drawn off and its disposal, and the disposal of flushings.
PART VII
FUEL GRADE CHANGES
1. Changes of grades of Aviation fuels in storage tanks,
fuelling vehicles and hydrant dispensers can pose a risk of
contamination of the new grade by residues of the previous
grade stored. This risk is of most significance when
changing from a 'leaded' fuel such as AVGAS 100LL to
Aviation Turbine Fuels, due to the absorption of lead into
the system, particularly tank linings.
2. Changes should be avoided if possible, but where they are
unavoidable the whole of the system should be thoroughly
purged and cleaned before the new grade is introduced. When
changing from AVGAS to aviation turbine fuel the
installation filter systems should be modified as necessary
to conform with the more demanding filtration specifications
for aviation turbine fuel set out in the preceding Parts of
this CAR.
PART VIII
SAMPLING PROCEDURES
1. GENERAL:
1.1 The purpose of sampling checks is to ensure that fuel
intended for use in aircraft is in a fit state for that use.
1.2 Fuel should be assessed as unsatisfactory for use in
aircraft if a sample shows:
i) more than a trace of sediment;
ii) globules of water;
iii) cloudiness;
1.3 A sample can be checked by visual inspection to ensure that
it does not contain excessive sediment, is generally clean,
and is of the colour appropriate to its grade. AVGAS is
blue; aviation turbine fuels are undyed and clear; but fuel
from different sources of production may vary in colour.
However, apart from cases where it is present in globules
and thus readily evident, a conclusive check on the presence
of water in fuels can only be made using the aids mentioned
in 1.2 (iv) above.
1.4 Free water may be present in AVGAS and both free and
suspended water in aviation turbine fuels. Water finding
paste or paper is designed to show the presence of free
water, and should be used for checks on all grades of fuel.
The chemical water detector (aquadis capsule) is designed to
detect suspended water and should be used therefore in
addition to paste or paper when checking aviation turbine
fuels.
2. PROCEDURES:
2.1 Water finding paste applied to the end of a dipstick should
be used for direct checking of fuel in bulk storage,
fuelling vehicles or barrels. Fresh paste should be used
for each check and the dipstick allowed to rest on the tank
or barrel bottom for no longer than ten seconds.
2.2 In the case of above ground storage tanks and aircraft
fuelling vehicles, samples should be drawn from sampling of
drain cocks, or with buried tanks by means of a thief pump.
Samples from barrelled supplies should be drawn with a glass
or plastic pipette.
2.3 Sufficient fuel should be drawn to enable a full and
conclusive check of the state of the fuel to be completed.
As a general guide when sampling from fuel company delivery
vehicles, bulk storage and aircraft fuelling vehicles it is
recommended that 3/4-1 gallon (31/2-41/2 litres) is drawn
from each compartment or sample drain. With barrelled
supplies or for the after fuelling check on hydrant
dispensers, a sample of about one pint will generally be
sufficient.
2.4 Ideally the sample should be drawn into a clear glass bottle
or jar, though if this is not available a stainless steel or
aluminium bucket should be used, which should be bonded to
the installation. Containers made of any other material
should not be used.
2.5 Check that the sample is the correct colour for its grade,
for sediment, water globules, cloudiness and general
cleanliness. Check for free and suspended water using water
finding paste or paper, and the chemical water detector in
the case of aviation turbine fuels. The presence of free or
suspended water is indicated by a distinct change in the
colour of the paste, paper or detector element.
2.6 All sampling equipment should be maintained in a
scrupulously clean condition.
2.7 If a series of samples taken from an installation are
unsatisfactory, immediate action should be taken to identify
the cause. No fuel should be dispensed from the
installation until this has been done, the appropriate
measures to prevent a recurrence of the contamination have
been completed, and further sampling checks shows that the
fuel in the installation is fit for use in aircraft.
PART IX
TESTING OF AVIATION PRODUCTS
1. Aviation products must be delivered in the same `on
specification' condition in which they were procured from
the producing refineries. From the refineries, aviation
products are transported by various methods such as Ocean
Tankers, Tank wagons, Tank Trucks, Refuellers, Dispensers
and packed containers to the final consuming points i.e.
aircraft. During this transportation, the aviation products
are also stored for certain periods at various intermediate
stages such as Terminals, Depots and Aviation Storage Points
before the final delivery to the aircraft.
1.1 To ensure that the aviation products received from refinery
are "on specification" and to maintain the same level of
quality throughout the transport and storage till delivered
to the aircraft, various types of laboratory as well as
field testings at different stages are essential.
1.2 The type of tests with characteristics for which the tests
to be conducted are furnished in the following pages.
Frequency of such tests should be covered in Quality Control
Manual.
1.3 Strict following of the procedures laid down shall ensure
the quality of the products transported, handled, stored and
delivered are maintained till the end and also whether or
not the "existing controls" are adequate and effective. As
such, the testings at laboratory and field levels are most
important.
2. Sampling Procedure:
2.1 Introduction:
1. Visual examination
2. Short test
3. Monitoring test
4. Laboratory inspections or full tests
5. Preservation of records.
2.2 Proper sampling is important, as improper sampling shall
lead to unfavourable test results even though the product
may be on specification. Procedures enumerated below must
be implicitly followed whenever samples are drawn.
2.3 Types of samples.
Different types of samples are drawn depending on type of
tests to be conducted. Reference of depth of sampling is
always taken from the top surface of the product.
1. Upper sample:- One taken at a level of 1/6th of the
depth of the product below the top surface.
2. Middle sample:- One taken at a level of one-half of
the product below the top surface.
3. Lower sample:- One taken at a level of 5/6th of the
depth of the product below the top surface.
4. Single tank composite sample:- For a tank of uniform
cross-section, a composite sample consists of a blend
of equal parts of upper, middle and lower samples.
5. Bottom sample:- One taken from within about 12mm of
the bottom surface of the tank or from the lowest point
of a pipeline.
6. All level sample:- One which is collected by
submerging a closed sample bottle to the bottom of the
tank, then opening the sample bottle and raising it at
a uniform rate so that it will not be completely filled
as it emerges out from the product ensuring the entry
of the product into the bottle at all levels.
2.4 General precautions to be observed while drawing samples.
1. Sampling shall be carried out during the coolest part
of the day preferably before 8 a.m. to reduce
evaporation loss.
2. Sampling shall be carried out in an area which is
shaded from the sun and protected from wind and dust.
3. Sampling shall be done by a responsible person fully
aware of the sampling procedures.
4. It shall be ensured that all necessary sampling
equipment is at hand and ready for use. The equipment
shall be absolutely clean, dry and in good condition.
5. Separate sampling equipment shall be used for each
product.
6. Sampling equipment and sample containers shall be
rinsed out several times with the product to be sampled
and allowed to drain before finally drawing the sample.
7. Sample containers shall be protected from the weather
and shall be closed immediately after the samples are
collected.
8. Sufficient space shall be left in container to take
care of product expansion.
2.5 Sampling Equipment:
1. A weighted can or bottle with stopper.
2. A tube or sampling thief of glass or metal suitable for
sampling 200 liter barrel.
3. Bottom sampling thief.
4. Decanting funnel.
5. Sample containers - one liter colored bottles or 2
liters aluminium containers suitably encased in felt
wooden boxes.
2.6 Procedures:
Bottom sample: Lower the sample thief to the bottom of the
tank. On touching the bottom the extended lever will rise
opening the bottom valve. Hold the thief for 2/3 minutes in
this position to allow the product to enter from bottom and
fill up the thief. Slowly raise the thief for the lever to
come down and close the opening at the bottom of thief.
Pull the thief out of the tank and transfer the product into
a bottle or sampling can.
All level sample - lower the stoppered bottle to the bottom
of the tank, pull out the stopper with a sharp jerk of the
chain (non-sparking) and raise the bottle/can at such a
uniform rate that it is nearly but not quite full as it
emerges from the product level.
Upper, Middle and Lower samples:- Lower the sampling
equipment to the selected level, pull out the stopper with a
sharp jerk of the chain and allow the bottle/can to fill
completely by keeping it at the selected level. After
complete filling draw out the equipment and replace stopper
immediately.
2.7 Barrels:
Barrels should be kept upright, tilted and sampled from the
top. Remove the bung, close the upper end of the clean dry
sampling tube with the thumb and lower the tube into the
product a depth of about 30 cms. Remove the thumb allowing
the product to flow into the tube. Again close the upper
end with the thumb and withdraw the tube. Allow the product
to rise in the tube by turning the tube horizontally and
discard this product. Again lower the tube into the drum
holding the thumb against the upper end. When the tube
reaches the bottom remove the thumb and allow the tube to
fill. Replace the thumb, withdraw the tube quickly and
transfer the contents into sample container.
2.8 Sample containers shall be labeled immediately after the
sample is collected and despatched to the laboratory. The
label shall contain the following information:
1. Grade of product
2. Serial No. of the sample
3. Location
4. Sampled by
5. Date and time of sampling
6. Source of sample (Tank No.)
7. Type of sample (Bottom/All level)
8. Quantity of product represented
9. Reason for sampling
10. Batch Number
11. Testing laboratory
12. Test required
2.9 Samples for testing shall be despatched as per
requirement.
2.10 Containers shall be ensured to be leak-proof.
2.11 Material used as washer for tight closing shall be resistant
to the product.
3. Laboratories:
3.1 Aviation products shall be subjected for various tests in a
Refinery Laboratory or Marketing laboratory approved by DGCA
under CAR Series 'E' Part IV.
3.2 Frequency of tests for aviation products and other fluids
shall be as detailed in Quality Control Manual and as per
requirements.
3.3 Laboratories shall have necessary standard testing
equipments to conduct the concerned tests.
3.4 In case of non-availability of a particular testing
equipment in an approved laboratory, such tests shall be
conducted in another approved laboratory where such
equipment is available and the test result indicated in test
reports accordingly with a notation.
3.5 Calibrated testing accessories such as thermometers,
Hydrometers and Pressure Gauges, etc. shall be checked for
accuracy once a year with a Master item of the respective
accessory.
3.6 Master items shall be calibrated once in 5 years.
3.7 Chief Chemists, Senior Chemists, Chemists and Junior
Chemists of approved marketing laboratories who meet the
requirements for Test Reports signatories under CAR Series
E, shall be considered for approval by DGCA as Test Report
Signatories.
3.8 Chief Chemists, Dy. Chief Chemists, Chemists, Quality
Control Managers, Dy. Quality Control Managers, Sr. Quality
Control Officers and Quality Control Officers of approved
Refinery laboratories meeting the requirements of Test
Report Signatories under CAR Series `E' shall be considered
for approval by DGCA as Test Report Signatories.
3.9 Aviation product test report issued by a DGCA approved
laboratory shall be signed and released by such an approved
Test Report Signatory only.
3.10 Any additions or changes in the personnel set-up at an
approved laboratory with regard to approved test report
signatories, shall be intimated to Quality Control Manager,
Head Office immediately for advising the DGCA to update
their records.
Sd/-
(S. L. Srivastava)
Deputy Director General of Civil Aviation