00-25-172 Chap-4

Flightline Servicing Operations

• Powered support equipment (SE) must be positioned and operated according to specific requirements:
  • Shut down all non-essential support equipment prior to servicing
  • Park support equipment outside the fuel servicing safety zone of the aircraft being serviced
  • Apply parking brakes and use chocks as necessary
  • Avoid pointing exhaust outlets at the aircraft when starting powered support equipment
  • Avoid touching exhaust manifold if unsure of its temperature
• Refueling vehicles shall not be driven or parked closer than 25 feet from an aircraft unless a spotter is used to direct the vehicle
  • Exceptions apply to certain aircraft models, such as the B-1, C-5, C-17, and C-130

Aircraft Refueling

• Fire and explosion hazards are always present during aircraft fuel servicing operations
• Vehicle and equipment operational checklists are mandatory
• Ensure required fire protection is in place and personnel not required for servicing leave the fuel servicing safety zone
• The APU/GTC will not be used during fueling operations on aircraft not specifically listed
• Bond the fuel servicing vehicle and equipment to the aircraft
• For over-the-wing/open-port fuel servicing, always bond the nozzle to the aircraft before removing the fill cap
• Monitor the control panel meters and gauge system during fueling and be prepared to shut down in case of a fuel leak or malfunction
• Prohibit the use of means to defeat the deadman control installed on fuel servicing equipment

Multiple Source Refueling

• Multiple source refueling is prohibited on medical evacuation aircraft when patients are on board or during enplaning/deplaning
• Refueling operators must continuously monitor refueling flow meters for correct indication of fuel flow
• Ensure the Defuel Override Control Valve is in the off position and locked (Oshkosh R-11) and the Red Protective Cover is closed (1st and 2nd generation Kovatch R-11) prior to starting fuel operations
• Multiple source refueling can be accomplished on certain aircraft models, such as the Airbus A300/A310, C-5, C-17, C-18/B-707, C-137, KC-135/T, E-4B, B-747, B-777, VC-25, DC-8, DC-10, KC-10, MD-11, and L-1011

Aircraft Defueling

• Defueling procedures are similar to refueling procedures, with additional requirements:

  • Drain all water from aircraft sumps prior to defueling
  • Determine the fuel grade by consulting the aircraft AFTO 781 series forms/record
  • Retain a fuel sample for visual examination if contamination is suspected
  • Do not pressurize the vehicle or equipment hoses with the single point nozzle open and the aircraft valve in defueling position### Defueling and Refueling Operations

• During defueling with specific fuel servicing vehicles (e.g., Condiesel, Kovatch, Oshkosh), ensure the high-level shutoff is operational.

• For all other units, have an individual observe the fuel level and signal the pump operator when the unit is full.

Fuel Servicing Safety Zone

• Ensure electrical power cables are at least 50 feet away from fuel servicing vehicles and equipment, and outside the fuel servicing safety zone.
• Preferably, park the power unit upwind.

Fuel Draining and Recovery

• Fuel drained from aircraft sumps should not be allowed to free-fall.
• Fuel that cannot be evacuated by normal truck or hydrant defueling operations may be drained into a rubber pail, clean metal container, or bowser.
• Mark the container with the grade of the product being collected and restrict it to this use only.
• Bond metal containers or bowsers to the aircraft during draining operations.
• All fuel drained from aircraft sumps shall be recovered by aircraft maintenance, sampled, and visual analysis performed by qualified fuels personnel.

ARFF Vehicle Requirements

• An ARFF vehicle must be on the scene when:
  • Defueling an aircraft with a fuel leak in the system or under emergency conditions resulting from damage.
  • Defueling under conditions requiring drainage of fuel into open containers or drums.
  • Defueling aircraft at a location where established safety distance criteria cannot be met.

APU/GTC Use During Refueling and Defueling

• The aircraft APU/GTC may be used to supply electrical power for single-point fuel servicing and defueling of specific aircraft.
• The APU/GTC will not be used during fueling operations on aircraft not specifically listed.
• Precautions apply during this operation, including:
  • Having a person outside the aircraft with a fire extinguisher if the aircraft is not equipped with an integral APU fire-fighting system.
  • Having a person at the APU/GTC controls at all times during fuel servicing operations.
  • Ensuring the APU/GTC is started and running in a stable condition prior to pressurizing the refueling hose or pantograph.

Initial Filling Operations of Aircraft with Foam-Filled Fuel Tanks

• Numerous internal flash fires have occurred within aircraft blue foam-filled tanks during refueling due to electrostatic ignition.
• Fuel flowing through reticulated urethane foam at high velocities can generate sufficient electrostatic charge to produce incendiary spark discharges.
• A fuel conductivity additive is now added to all JP-4 and JP-8 fuels to minimize the generation of static charges.
• However, initial filling must still be accomplished at a reduced flow rate when fueling new or recently repaired aircraft bladder tanks that are in a vapor-free condition.

Filling Fuel Servicing Vehicles from Hydrant Systems

• Refueling units are sometimes filled on the flight line using a hose cart or hydrant servicing vehicle.
• The distance criteria established for aircraft refueling apply.
• Procedures established in specific technical orders shall be followed.

Servicing in Aircraft Alert, Hardened/Protective Aircraft Shelters (HAS/PAS), or Flow Through Revetments (FTR)

• For emergency situations, immediately cease all operations, notify the fire department, use available fire extinguishers when needed, and evacuate nonessential personnel from the area.
• When servicing in aircraft alert, HAS/PAS shelters, or FTR, the following applies:
  • Aircraft may utilize CSO procedures as approved by SSEA for simultaneous operations.
  • The fuel servicing safety zone criteria shall be complied with.
  • Refueling will not start until all nonessential personnel and equipment have been removed from the area.
  • During servicing operations, restrictions will be placed on the entry of nonessential personnel or equipment into the servicing area.

Flightline Servicing Operations

• Powered support equipment (SE) must be positioned and operated according to specific requirements:
  • Shut down all non-essential support equipment prior to servicing
  • Park support equipment outside the fuel servicing safety zone of the aircraft being serviced
  • Apply parking brakes and use chocks as necessary
  • Avoid pointing exhaust outlets at the aircraft when starting powered support equipment
  • Avoid touching exhaust manifold if unsure of its temperature
• Refueling vehicles shall not be driven or parked closer than 25 feet from an aircraft unless a spotter is used to direct the vehicle
  • Exceptions apply to certain aircraft models, such as the B-1, C-5, C-17, and C-130

Aircraft Refueling

• Fire and explosion hazards are always present during aircraft fuel servicing operations
• Vehicle and equipment operational checklists are mandatory
• Ensure required fire protection is in place and personnel not required for servicing leave the fuel servicing safety zone
• The APU/GTC will not be used during fueling operations on aircraft not specifically listed
• Bond the fuel servicing vehicle and equipment to the aircraft
• For over-the-wing/open-port fuel servicing, always bond the nozzle to the aircraft before removing the fill cap
• Monitor the control panel meters and gauge system during fueling and be prepared to shut down in case of a fuel leak or malfunction
• Prohibit the use of means to defeat the deadman control installed on fuel servicing equipment

Multiple Source Refueling

• Multiple source refueling is prohibited on medical evacuation aircraft when patients are on board or during enplaning/deplaning
• Refueling operators must continuously monitor refueling flow meters for correct indication of fuel flow
• Ensure the Defuel Override Control Valve is in the off position and locked (Oshkosh R-11) and the Red Protective Cover is closed (1st and 2nd generation Kovatch R-11) prior to starting fuel operations
• Multiple source refueling can be accomplished on certain aircraft models, such as the Airbus A300/A310, C-5, C-17, C-18/B-707, C-137, KC-135/T, E-4B, B-747, B-777, VC-25, DC-8, DC-10, KC-10, MD-11, and L-1011

Aircraft Defueling

• Defueling procedures are similar to refueling procedures, with additional requirements:

  • Drain all water from aircraft sumps prior to defueling
  • Determine the fuel grade by consulting the aircraft AFTO 781 series forms/record
  • Retain a fuel sample for visual examination if contamination is suspected
  • Do not pressurize the vehicle or equipment hoses with the single point nozzle open and the aircraft valve in defueling position### Defueling and Refueling Operations

• During defueling with specific fuel servicing vehicles (e.g., Condiesel, Kovatch, Oshkosh), ensure the high-level shutoff is operational.

• For all other units, have an individual observe the fuel level and signal the pump operator when the unit is full.

Fuel Servicing Safety Zone

• Ensure electrical power cables are at least 50 feet away from fuel servicing vehicles and equipment, and outside the fuel servicing safety zone.
• Preferably, park the power unit upwind.

Fuel Draining and Recovery

• Fuel drained from aircraft sumps should not be allowed to free-fall.
• Fuel that cannot be evacuated by normal truck or hydrant defueling operations may be drained into a rubber pail, clean metal container, or bowser.
• Mark the container with the grade of the product being collected and restrict it to this use only.
• Bond metal containers or bowsers to the aircraft during draining operations.
• All fuel drained from aircraft sumps shall be recovered by aircraft maintenance, sampled, and visual analysis performed by qualified fuels personnel.

ARFF Vehicle Requirements

• An ARFF vehicle must be on the scene when:
  • Defueling an aircraft with a fuel leak in the system or under emergency conditions resulting from damage.
  • Defueling under conditions requiring drainage of fuel into open containers or drums.
  • Defueling aircraft at a location where established safety distance criteria cannot be met.

APU/GTC Use During Refueling and Defueling

• The aircraft APU/GTC may be used to supply electrical power for single-point fuel servicing and defueling of specific aircraft.
• The APU/GTC will not be used during fueling operations on aircraft not specifically listed.
• Precautions apply during this operation, including:
  • Having a person outside the aircraft with a fire extinguisher if the aircraft is not equipped with an integral APU fire-fighting system.
  • Having a person at the APU/GTC controls at all times during fuel servicing operations.
  • Ensuring the APU/GTC is started and running in a stable condition prior to pressurizing the refueling hose or pantograph.

Initial Filling Operations of Aircraft with Foam-Filled Fuel Tanks

• Numerous internal flash fires have occurred within aircraft blue foam-filled tanks during refueling due to electrostatic ignition.
• Fuel flowing through reticulated urethane foam at high velocities can generate sufficient electrostatic charge to produce incendiary spark discharges.
• A fuel conductivity additive is now added to all JP-4 and JP-8 fuels to minimize the generation of static charges.
• However, initial filling must still be accomplished at a reduced flow rate when fueling new or recently repaired aircraft bladder tanks that are in a vapor-free condition.

Filling Fuel Servicing Vehicles from Hydrant Systems

• Refueling units are sometimes filled on the flight line using a hose cart or hydrant servicing vehicle.
• The distance criteria established for aircraft refueling apply.
• Procedures established in specific technical orders shall be followed.

Servicing in Aircraft Alert, Hardened/Protective Aircraft Shelters (HAS/PAS), or Flow Through Revetments (FTR)

• For emergency situations, immediately cease all operations, notify the fire department, use available fire extinguishers when needed, and evacuate nonessential personnel from the area.
• When servicing in aircraft alert, HAS/PAS shelters, or FTR, the following applies:
  • Aircraft may utilize CSO procedures as approved by SSEA for simultaneous operations.
  • The fuel servicing safety zone criteria shall be complied with.
  • Refueling will not start until all nonessential personnel and equipment have been removed from the area.
  • During servicing operations, restrictions will be placed on the entry of nonessential personnel or equipment into the servicing area.

Flightline Servicing Operations

• Powered support equipment (SE) must be positioned and operated according to specific requirements:
  • Shut down all non-essential support equipment prior to servicing
  • Park support equipment outside the fuel servicing safety zone of the aircraft being serviced
  • Apply parking brakes and use chocks as necessary
  • Avoid pointing exhaust outlets at the aircraft when starting powered support equipment
  • Avoid touching exhaust manifold if unsure of its temperature
• Refueling vehicles shall not be driven or parked closer than 25 feet from an aircraft unless a spotter is used to direct the vehicle
  • Exceptions apply to certain aircraft models, such as the B-1, C-5, C-17, and C-130

Aircraft Refueling

• Fire and explosion hazards are always present during aircraft fuel servicing operations
• Vehicle and equipment operational checklists are mandatory
• Ensure required fire protection is in place and personnel not required for servicing leave the fuel servicing safety zone
• The APU/GTC will not be used during fueling operations on aircraft not specifically listed
• Bond the fuel servicing vehicle and equipment to the aircraft
• For over-the-wing/open-port fuel servicing, always bond the nozzle to the aircraft before removing the fill cap
• Monitor the control panel meters and gauge system during fueling and be prepared to shut down in case of a fuel leak or malfunction
• Prohibit the use of means to defeat the deadman control installed on fuel servicing equipment

Multiple Source Refueling

• Multiple source refueling is prohibited on medical evacuation aircraft when patients are on board or during enplaning/deplaning
• Refueling operators must continuously monitor refueling flow meters for correct indication of fuel flow
• Ensure the Defuel Override Control Valve is in the off position and locked (Oshkosh R-11) and the Red Protective Cover is closed (1st and 2nd generation Kovatch R-11) prior to starting fuel operations
• Multiple source refueling can be accomplished on certain aircraft models, such as the Airbus A300/A310, C-5, C-17, C-18/B-707, C-137, KC-135/T, E-4B, B-747, B-777, VC-25, DC-8, DC-10, KC-10, MD-11, and L-1011

Aircraft Defueling

• Defueling procedures are similar to refueling procedures, with additional requirements:

  • Drain all water from aircraft sumps prior to defueling
  • Determine the fuel grade by consulting the aircraft AFTO 781 series forms/record
  • Retain a fuel sample for visual examination if contamination is suspected
  • Do not pressurize the vehicle or equipment hoses with the single point nozzle open and the aircraft valve in defueling position### Defueling and Refueling Safety Procedures

• Defueling suction hose extension (Pigtail) does not require bonding.

• Verify high level shutoff is operational during defueling with Condiesel (1981) R-9, Kovatch R-9, and Oshkosh R-11 fuel servicing vehicles.

• Ensure an individual observes fuel level and signals the pump operator when the unit is full for all other units.

• Electrical power cables should be at least 50 feet away from fuel servicing vehicles and equipment, outside of the fuel servicing safety zone, and preferably upwind.

• Fuel drained from aircraft sumps should not be allowed to free-fall.

• Fuel that cannot be evacuated by normal truck or hydrant defueling operations may be drained into a rubber pail (NSN 7240-01-150-0716 only), clean metal container, or bowser.

• Mark the container with the grade of the product being collected and restrict to this use only.

• Bond metal container or bowser to aircraft during draining operations.

ARFF Vehicle Requirements

• An ARFF vehicle must be on the scene when defueling an aircraft with a fuel leak in the system or under emergency conditions.
• ARFF vehicle is required when defueling under conditions requiring drainage of fuel into open containers or drums.
• ARFF vehicle is required when defueling aircraft at a location where established safety distance criteria cannot be met.

APU/GTC Use During Refueling and Defueling

• Aircraft APU/GTC may be used to supply electrical power for single-point fuel servicing and defueling of specific aircraft.
• The APU/GTC will not be used during fueling operations on aircraft not specifically listed.
• Precautions apply during this operation, including:
  • Having an individual with a 150-pound Halon 1211 fire extinguisher outside the aircraft within 20 feet of the APU/GTC compartment exhaust.
  • Having one person at the APU/GTC controls at all times during fuel servicing operations.
  • Ensuring cockpit personnel, CSS, and fuel servicing supervisor are in constant voice contact.

Initial Filling Operations of Aircraft with Foam-Filled Fuel Tanks

• Reduced flow rate refueling procedures are required when fueling new or recently repaired aircraft bladder tanks that are in a vapor-free condition.
• Fuel conductivity additive is added to all JP-4 and JP-8 fuels to minimize the generation of static charges.
• Initial filling must be accomplished at a reduced flow rate to minimize the risk of electrostatic ignition.

Filling Fuel Servicing Vehicles from Hydrant Systems

• Refueling units may be filled on the flight line using a hose cart or hydrant servicing vehicle.
• Distance criteria established for aircraft refueling apply.
• Procedures established in TO 37A2-2-4-1CL-1, Appendix B, or 36A12-13-31-1CL-1 shall be followed.

Servicing in Aircraft Alert, Hardened/Protective Aircraft Shelters (HAS/PAS), or Flow Through Revetments (FTR)

• Cease all operations and notify the fire department in emergency situations.
• Follow MDS specific technical order procedures for aircraft reconfiguration, servicing, inspections, and munitions loading/unloading.
• Only authorized activities specified in aircraft technical orders will be performed in conjunction with aircraft servicing.
• Servicing operations inside shelters/FRS present a greater degree of risk.

Reduced Flow Rate Refueling Procedures

• Used when fuel-servicing vehicles are the pumping source
• Only one hydrant pump will be activated
• Procedures apply to all Air Force owned aircraft and non-Air Force aircraft meeting specific fuel cell/tank conditions, being refueled on an Air Force base

Filling Fuel Servicing Vehicles from Hydrant Systems

• Refueling units can be filled on the flight line using a hose cart or hydrant servicing vehicle
• Distance criteria for aircraft refueling in Table 3-2 apply
• Procedures in TO 37A2-2-4-1CL-1, Appendix B, or 36A12-13-31-1CL-1 shall be followed

Servicing in Aircraft Alert, Hardened/Protective Aircraft Shelters (HAS/PAS), or Flow Through Revetments (FTR)

• Cease all operations in emergency situations and notify the fire department
• Use available fire extinguishers when needed
• Evacuate nonessential personnel from the area
• Open Hardened/Protective Aircraft Shelter doors
• Aircraft may utilize CSO procedures as approved by SSEA for simultaneous operations
• MDS specific technical order procedures for aircraft reconfiguration, servicing, inspections, and munitions loading/unloading will be followed
• Servicing operations inside shelters/FRS present a greater degree of risk than the same operations conducted outside on open ramp

Unique Requirements When Servicing in Hardened/Protective Aircraft Shelters (HAS/PAS)

• Electrical standards of the National Electrical Code for Class I, Division 2 (Zone 2) hazardous locations apply
• Restrictions on electrical power and wall/under-wing lights in first and modified first generation HAS/PAS
• Positioning of electrical circuits and switches shall not be changed during fuel servicing operations

Aircraft Fuel Servicing in Type A/F 37T10/11 Hush Houses (Enclosed Aircraft/Engine Noise Suppressor Systems)

• Fuel servicing vehicles may be positioned outside or inside of hush houses for fuel servicing operations
• Specific procedures for fuel servicing in hush houses to alleviate the necessity to tow an aircraft 50 feet outside a hush house to accomplish fuel servicing before continuing engine test runs

Fuel Servicing Explosives Loaded Aircraft

• Aircraft is considered "explosives-loaded" when munitions or explosives are carried either internally or externally
• Fuel servicing explosives-loaded aircraft requires meeting acceptable quantity-distance (Q-D) criteria when the munitions aboard are SAFED according to the specific aircraft -33-1-2 munitions loading manual
• Specific procedures for fuel servicing explosives-loaded aircraft in different scenarios (e.g., fighter or bomber, cargo aircraft)

Fuel System Maintenance Facilities

• Aircraft fuel servicing is permitted in fuel system maintenance facilities (fuel cell) complying with the facility requirements of TO 1-1-3

Fuel Servicing in Hangars and Other Facilities

• Aircraft fuel servicing is permitted in hangars and similar facilities where aircraft engines are started inside and the aircraft taxies out flight-ready
• Specific provisions must be in good working order, including ventilation system, drainage system, automatic foam-water fire suppression system, and electrical provisions designed for Class I, Division 1 (Zone 1) hazardous locations

Oxygen Servicing

• Gaseous oxygen (O2) is colorless, odorless, tasteless, but supports rapid combustion of most materials and reacts violently with petroleum products
• Liquid oxygen (LOX) is a pale blue liquid, which exists in the liquid state only at an extremely low temperature (-182.5 ºC or -297 ºF)
• Oxygen servicing equipment shall be kept clean and free of moisture, oil, and grease at all times
• Specific procedures for parking and storing LOX carts containing LOX and oxygen bottle carts containing gaseous oxygen### Safety Precautions for Oxygen Servicing
• Do not allow oxygen to contact petroleum products as fire or explosion may result.
• Keep a 20-foot radius safety zone around liquid oxygen servicing, and ensure personnel not directly involved stay outside this area.
• Turn off cellular phones, hand held radios, and other transmitting devices within 50 feet of the servicing area.
• Servicing personnel must wear personal protective equipment, ensure their hands, feet, and clothing are clean and free of petroleum-based products.

Qualified Personnel and Equipment

• Only qualified personnel shall operate oxygen equipment or service aircraft systems.
• Ensure oxygen servicing connectors are examined and cleaned prior to servicing.
• Ground and bond oxygen servicing equipment according to TO 15X-1-1.

Gaseous Oxygen Servicing

• Do not direct gaseous oxygen towards body or clothing, as serious injury or death may result from the high energy of compressed gas and/or fire.
• Maximum pressure regulator valve setting for low-pressure oxygen systems is 475 psig.
• Ensure oxygen servicing components are completely free of petroleum-based products.
• Open and close high-pressure oxygen valves slowly to avoid heating by sudden compression.

Safety Procedures

• Eye protection (safety goggles, safety glasses with side shields, or face shield) shall be worn by personnel performing oxygen servicing at aircraft connection point.
• Statically ground the LOX Servicing Cart to a common ground before connecting servicing hose.
• Personnel shall observe aircraft oxygen gauges at all times during servicing operations to prevent overfilling of tanks.
• One person can accomplish servicing if the aircraft oxygen system gauges can be observed to prevent overfilling while stationed at the oxygen servicing unit.

Liquid Oxygen Servicing

• Do not allow LOX to contact petroleum products as fire or explosion may result.
• LOX will freeze and seriously damage human skin tissue upon contact.
• If LOX spills on asphalt or concrete expansion joint sealant, stop servicing or other operations within a 20-foot radius of spilled area for at least 30 minutes.
• Prevent further injury to the frozen area and transport immediately to the emergency room of the nearest medical facility.
• Ensure a serviceable 150-pound wheeled Halon 1211 fire extinguisher or equivalent is placed within 50 feet of the LOX servicing operation.

Protective Clothing and Equipment

• When transferring LOX, personnel shall wear headcovering, face shield, gloves, leather, welder’s gauntlet cuff, medium with gloves, cloth, work, cotton knit, apron, coveralls, cotton white, cuffless trousers, long sleeve shirt, jacket, and shoes with rubber soles and heels.
• All items shall be clean and free of grease, oil, and fuel.
• A BDU cap is recommended as head covering when LOX servicing connections are above eye level since it would afford more protection than the adjustable style cap with open back.