Aircraft Servicing Safety PDF

The worst possible accident is an aircraft accident with associated loss of life and damage to property. This results in tremendous financial loss through insurance pay outs, damage or loss of property, and aircraft damage or loss. Accidents are associated with the following factors: 88% due to uns...

The worst possible accident is an aircraft accident with associated loss of life and damage to property. This results in tremendous financial loss through insurance pay outs, damage or loss of property, and aircraft damage or loss. Accidents are associated with the following factors: 88% due to unsafe acts; 10% due to an unsafe physical and mechanical condition 2%act of Providence To achieve the objective of the course we will look at Aircraft Servicing Safety under the following headings; Sense, Aircraft, Fire, Evacuation, Technical, You. AIRCRAFT SERVICING SAFETY S ENSE A IRCRAFT FI RE EVACUATION TECHNICAL Y ou COMMON SENSE The knowledge or experience level of a person can be put down to sense. Some people tend to call it common sense. Common sense is a development since birth through own experience and by observing others. The lack of common sense causes most accidents. There is a need to develop this sense for the aircraft environment, specifically through training, as the 'live and learn' and 'once bitten twice shy' attitudes can not be afforded. ATTITUDE AND CHARACTER Attitude and character can only improve through training. An aviation technician, irrespective of trade, always shows positive attitude and character. This invokes responsibility, resulting in respect for rules and regulations regarding aircraft, its equipment and crew. CONDUCT AND BEHAVIOUR Many accidents are caused by the clown or practical joker in the working area. It is every worker's responsibility to adhere to workshop rules and regulations. Avoid practical jokes and 'games' as they are annoying as well as dangerous. RESPONSIBILITY It is not only Management's responsibility to avoid an unsafe act or condition. It is everybody's responsibility to develop safe working habits and use safeguards and protective equipment properly. Be mindful of fellow workers and safety while giving full attention to your own. Respect workshop rules and regulations. KNOWLEDGE OF RULES AND REGULATIONS Regulations are prescribed rules, directives or instructions defining how certain jobs should be conducted, i.e. sequence to be followed, precautions to be taken, etc. Rules and regulations ensure the safety of all workers. Ensure you understand the regulations, instructions and precautions before undertaking a task. HOUSE KEEPING ADVANTAGES OF GOOD HOUSE KEEPING It saves time ➤ It saves space ➤ Walkways and gangways are kept clear ➤ It reduces the possibility of a fire hazard ➤ It creates a safe workplace RESULTS OF BAD HOUSEKEEPING ➤ Tripping over goods ➤ Articles dropping off upper surfaces and/or shelves. Slippage on oils or fuel ➤ Fires caused by fuel spillage ➤ Damage to aircraft and/or property ➤ Injury due to protruding aircraft areas like a pitot or wing tip ➤ Foreign Object Damage (FOD) The rule of housekeeping is a place for everything and everything in its place. AIRCRAFT DANGER ZONES APPROACH AND ACCESS TO AIRCRAFT EJECTION SEATS STANDARD AIRCRAFT MARKINGS WORKING ON AIRCRAFT FOREIGN OBJECT DAMAGE (F.O.D.) LOCKING DEVICES AIRCRAFT ELECTRICS PARKING OF AIRCRAFT MOVEMENT OF AIRCRAFT GROUND RUNNING AIRCRAFT REPLENISHMENT AND SERVICING SYMBOLS REFUEL AND DEFUEL PROCEDURES OIL REPLENISHMENT OXYGEN SYSTEMS LIQUID OXYGEN (LOX) JACKING OF AIRCRAFT DANGER ZONES All aircraft has designated danger zones due to moving or rotating assemblies or other systems. Information conceming these danger zones is normally published in the related manufacturer's manuals. The following are examples of danger zones. a)Propellers on fixed wing aircraft, rotors on helicopters, air-conditioner units, shafts, etc. are all examples of rotating assemblies and are potentially lethal. b)Heaters, heat exchangers, exhaust pipes, jet efflux, engines, etc. is all examples of heat sources. These heat sources can cause bum injuries to workers and are also potential fire hazards. c)Jet inlets on engines and air-conditioner units and propellers are all suction sources and should be avoided. d)Jet exhaust, prop wash on fixed wing aircraft and rotor down wash on helicopters are all velocity type hazards. Injury and damage can be caused by FOD being propelled by these velocity generators. e)When noise level exceeds 85 dB, it is mandatory to wear ear protection equipment. f)Ejection seats and explosive canopies are lethal weapons and all precautions must be adhered to. g)Services like fuel, oxygen, armour, electrical and hydraulics is all potentially dangerous and the precautions are normally published in the related manufacturer manuals. APPROACH AND ACCESS TO AIRCRAFT APPROACHING AN AIRCRAFT All aircraft has a safe approach way or area. These safe areas are published in the manufacturer's manuals. Red pennants and warnings like fur example 'hydraulic function test' must be adhered as potential dangers exist. ACCESS TO AIRCRAFT a)Normal access to aircraft is by means of steps, ladders, foot rests or associated systems. Entrance markings are normally black or yellow and possibly a red warning triangle if explosive devices are fitted. b)Aircraft canopies are heavy and could cause injury if not handled correctly. Prevent forcing canopies as different aircraft has different canopy hinges. c)Emergency access is by means of escape hatches or cut panels on bigger aircraft types, or canopy jettison on fighter type aircraft. Always refer to the applicable manufacturer manuals for the correct procedure. d)Waming markings are normally red and can be in the form of triangle or pennant attached to the service. Emergency markings are normally yellow or variations there of, for example a yellow and black chevron panel or yellow arrow. EJECTION SEATS Ejection seats fitted to fighter type aircraft are potentially lethal weapons. At least the main gun and drogue system fitted to the ejection seat are operated by explosive charges. A red waming triangle is normally painted on the side of the cockpit if an ejection seat or seats are fitted to an aircraft. Before entering or leaving a cockpit it is the individual's responsibility to ensure all safety pins are fitted as prescribed in the manufacturer manuals. STANDARD AIRCRAFT MARKINGS Standard marking normally conforms to ICAO for civil aircraft, or NATO Mil, Spec for military aircraft. These markings are normally fitted on, at or near a specific point of service. WORKING ON AIRCRAFT Refer to the specific aircraft manufacturer manual for the correct procedures and precautions to be used to carry out a task on the aircraft. Ensure that the correct tools, ladders, stands, trestles, jacks, guards, etc. are utilised for the task. Avoid playing 'hangar pilot' at all times as serious damage and/or injury can result. FOREIGN OBJECT DAMAGE (FOD) Insects, ice, stones, bolts, nuts, in fact any loose article can be classified as FOD. FOD can potentially be responsible for an accident. CONTROL OF FOD a)Control servicing debris like aircraft general spares (AGS), rags, blanks, wire, etc. b)Blank the airframe and/or structure to prevent ingress by FOD c)Fit protective guards in front of engine inlets when doing ground runs d)Blank service pipes and connections e)Filter oil, hydraulic fluid and fuel f)Sample oil, hydraulic fluid and fuel before use g)Keep the aircraft clean. Clear or wash bird droppings, dust, insects, etc. h)Blank vents and plugs or fit covers I)Mark tools and do a regular tool check by means of a shadow board system. When working in a difficult area, attach a string to the tool to assist retrieval in event ofdropping the tool j)When painting ensures that the aircraft is effectively masked k)Control rain and condensation to prevent water FOD I)hough icing seldom occurs it must be controlled properly m)Personal effects like watches, lighters, etc. should be stored in a locker. If not, ensure it is kept in a sealed pocket in the overall. LOCKING DEVICES Locking devices are fitted to prevent nuts and bolts from working loose due to the vibration levels in aircraft. A loose nut or bolt could cause a failure of some sort. There are various methods of locking, for example, split pins, lock nuts, wire-locking, etc. SELF LOCKING NUTS Self locking nuts need no auxiliary means of safetying. The safetying feature is designed as an integral part of the construction. Generally there are two types of manufacture in use, an all-metal type or a fibre-lock type. AIRCRAFT WASHERS Washers used in aircraft repair are either plain, lock or special type washers. Plain washers provide a smooth bearing surface and act as a shim in obtaining correct grip length for a bolt and nut assembly. They should be used under lock washers to prevent damage to the surface material. Lock washers are used with machine screws or bolts when self-locking or castellated type nut is not appropriate. The spring action provides enough friction to prevent loosening of the nut from vibration. Shakeproof lock washers are round washers designed with tabs or lips that are bent upwards across the sides of a nut or bolt to lock the nut in place. Special washers are used where a bolt is installed at an angle to a surface or where perfect alignment with a surface is required. TURN LOCK FASTENERS This load stressed panel fasteners are also known as quick-release or quick-action fasteners. The most desirable feature of these fasteners is that they permit quick and easy removal of access panels for inspection and servicing purposes. Some of the most commonly used fasteners are Dzus, Camloc and Airloc fasteners. SPLIT PINS (COTTER PINS) Castellated nuts are used with bolts that have been drilled for split pins. The split pin is used only once and should fit neatly into the hole with very little side play. WIRE LOCKING (SAFETY WIRING) Wire locking is the most positive and satisfying method of safetying cap screws, studs, nuts, bolt heads and tumbuckle barrels that cannot be safetied by any other practical means. It is a method of wiring together two or more units in such a manner that any tendency of one to loosen is counteracted by the tightening of the wire. CIRCLIP (SNAPRING) A circlip is a ring of metal, either round or flat in cross section, which is tempered to have spring like action. This spring like action will hold the Snapring firmly seated in a groove. The external types are designed to fit in a groove around the outside of a shaft or cylinder. The internal types are fitted into a groove inside a cylinder. Each type of circlip is installed with a special type of pliers. The external type circlip may be safety wired. AIRCRAFT ELECTRICS Most aircraft electrical circuits are a single wire or 'earth return' system where only one insulated cable runs to a component while the structure acts as a retum back to the supply. This necessitates a good 'earth' connection for current flow and bonding. Electrical power is supplied by an alternator, generator, transformer rectifier unit (TRU), inverter or ground power unit (GPU) for operation. BONDING For an effective 'earth return' system good electrical contact is achieved by bonding the various parts with copper earthing strips. It additionally avoids the build-up of dangerous electrostatic charges during flight, which could cause arcing. On the ground a similar system of bonding is utilised when the aircraft and servicing equipment is connected. SAFETY PRECAUTIONS a)Always consult the foreman or crew chief in charge before switching ON the power. b)Ensure power is OFF and power supplies (internal and external) are disconnected before removing or fitting equipment or plugs. c)Ensure all switches are OFF before connecting external power. d)No functional test of any electrical operated component is allowed during refueling or defuelling an aircraft. AIRCRAFT BATTERIES Lead-acid and nickel-cadmium batteries are the two most common types used in aircraft. These batteries possess different characteristics and, therefore, should be maintained in accordance with the manufacturer's recommendations. Aircraft batteries are identified by the material used for the plates. PARKING OF AIRCRAFT Aircraft should be parked in a hanger, on a hardstand, or a reasonably level hard surface. WHEEL CHOCKS Wheel chocks are placed at the front and rear of the main wheels as soon as the aircraft is in parking position after flight, taxi or towing. GROUND LOCKS Ground locks in the form of distance tubes, braces or struts are positioned or installed to make safe potential dangers such as landing gear, air brakes, bomb doors, hinged canopy hoods, wing folding mechanisms, propeller blades or rotor blades. SAFETY DEVICES Where applicable explosives such as ejection seats, canopy jettison systems or weapons systems, shall be safetied by means of their applicable safety pins or devises as described in the manufacturer manuals. Before entering or leaving an aircraft cockpit always ensure that the safety devices are installed. CONTROL LOCKS Control locks can be in the fom of special mechanisms in the cockpit or external locking devices. Control locks prevent damage to aircraft control surfaces and systems. PROTECTVE COVERS AND WEATHERPROOFING Depending on the circumstances at least the following covers should be fitted; pitot-static system, engine induction system and engine exhaust system. Additionally canopy covers and/or other aircraft covers can be fitted for medium or long term storage. HELICOPTER PARKING The parking, chocking, utilising of ground locks and protective covers, does not differ from fixed wing aircraft. The rotor systems are normally fitted with locking systems and the applicable manufacturer manuals should be consulted for the correct procedure. Helicopters might be fitted with skid type undercarriage making wheel chocks obsolete. MOVEMENT OF AIRCRAFT When it is required to move an aircraft for servicing or flight purposes, it will either be ground handled or towed. Ensure that the required locking devices on the undercarriage and control systems are fitted as prescribed in the manufacturer manuals. Refer to the manufacturer manuals for the correct equipment and procedure for the movement of aircraft. Ensure a set of wheel chocks is available in event of a brake system failure. The number of people in the party depends upon the aircraft type and size. The minimum required in a ground party is; a)A qualified and certified driver for the towing vehicle b)A qualified and certified person in the aircraft cockpit to operate the aircraft brake system c)A person at each wing tip maintaining a clearance watch. With helicopter movements the main rotor could be turned to avoid obstructions d)A person at the tail maintaining a clearance watch between the aircraft and overhead obstructions. AIRCRAFT GROUND RUNNING Only qualified and certified persons are allowed to execute ground running of aircraft. Refer to the applicable manufacturer manuals for the ground running procedure and precautions of the specific aircraft. GENERAL PRECAUTIONS a)The aircraft must be sited on firm level ground free from FOD b)All ground support equipment must be well clear of the aircraft c)The aircraft must be headed into the prevailing wind to ensure adequate airflow for inlet and cooling purposes d)The main wheels must be chocked and the park brake applied dle)If the aircraft is not to be flown the required guards must be fitted f)Ensure no property damage or personnel injury will occur from propellers, rotors, jet inlets or jet exhaust efflux g)Fire precautions must be taken. Ensure serviceable equipment and competent persons are utilised for this function h)Ensure all personnel are wearing adequate ear protection gear I)No loose personal articles, i. e. hats, scarves, etc. are allowed near aircraft ground running. AIRCRATE REPLENISHMENT AND SERVICING SYMBOLS Aircraft markings and symbols on military aircraft comply with NATO standards. These symbols indicate the allocation of services and/or wamings of potentially dangerous services. In order to be visible, the markings will always be in contrast to the prevailing background. PRECAUTIONS a)Adhere to the warning markings at all times b)Always refer to the manufacturer manuals for the procedure and precautions to be utilised for each service c)Before replenishing any services, refer to the manufacturer manuals to ensure the correct grade is used. AIRCRAFT REFUELLING AND DEFUELLING There are two methods of refueling on aircraft, gravity or pressure. GRAVITY REFUELING Tanks are filled through ports in the top of the tank, either by nozzle and hose from tankers or from small capacity fuel containers. All fuel should be delivered through a standard filter. PRESSURE REFUELLING Pressure refueling is the most rapid means of refueling the aircraft as the refueller is capable of supplying fuel at a high delivery rate. Chances of fuel contamination re reduced and ignition of fuel vapours by static electricity is also minimised. GENERAL PRECAUTIONS a)Due to varying refueling and defueling procedures refer to the manufacturer manuals for the correct procedure to be adopted for the specific aircraft b)Ensure the correct grade fuel and associated equipment is used c)Restrict personnel to the minimum required for the task d)No SMOKING signs must be posted. The correct type and serviceable fire extinguishers must be readily available e)Sources of ignition such as steel tools, studded boots, lighters, matches and unprotected lights must not be taken into the area f)Remove ground power units from the area g)All equipment including the aircraft, refueller and nozzles must be properly earthed through bonding h)Hoses and couplings must be checked and covers fitted to prevent contamination i)The refueller must be positioned enabling rapid moving in event of an emergency j)Aircraft must be moved from the area if fuel spillage occurred. Spilled fuel should be washed away as soon as possible by the emergency services. Clothing should be changed as soon as possible if the fuel was spilled on any person k)Ensure extra precautions are enforced when refueling or defueling inside the hangar l)No refuelling is allowed with aircraft engines running m(Monitor fuel tank ventilation outlets for any possible overflow. When overflow occurs shut off the refuelling equipment immediately. DEFUELLING OF AIRCRAFT Refer to the manufacturer manual to ensure the correct procedure is used for the aircraft. The precaution for defuelling is the same as for refuelling. OIL REPLENISHMENT Oil replenishment can be carried out by gravity or pressure feed with special ground equipment. Replenishment by means of the special ground equipment is preferred as contamination is less likely. GENERAL PRECAUTIONS a)Refer to the manufacturer manuals for the correct grade of oil to be used as well as the procedure to be adopted. b)Ensure absolute cleanliness to prevent contamination. Where required fit dust caps to nozzles and connectors. c)Only fill oil tanks to the required level as measured with a dipstick or sight glass d)Prevent oil spillage. Ensure containers do not damage the aircraft surface finish. OXYGEN SYSTEMS WARNING NOTE Oils, grease and solvents can ignite or explode spontaneously if they come in contact with pressurised oxygen. Recharging of oxygen cylinders generates heat. Subsequent cooling will cause the pressure to fall from the charged pressure to final recharging pressure. GENERAL PRECAUTIONS a)Recharging must never be carried out direct from a high pressure storage cylinder. A pressure reducing regulator must be used so that the system limit pressures cannot be exceeded b)Ensure all equipment is free from oils, greases and solvents c)Always use non-metallic tools to prevent accidental sparks d)Always fit approved blanking plugs to connections to prevent contamination. Do not use masking tape or rags to close the outlets. e)Aircraft should not be serviced with Oxygen during fuelling, defueling or other maintenance work that could provide a source of ignition. LIQUID OXYGEN SYSTEMS (LOX) CAUTION In addition to aggravating the fire hazard, LOX will cause severe frostbite if it comes in contact with the skin. This is due to the low temperature of LOX, -183 °C or -297°F. Refer to the applicable manufacturer manuals for precautions and the correct procedure to be adopted. Proper safety clothing, i.e. gloves and apron should be warn when working with LOX. The same general precautions for gaseous Oxygen apply to LOX. JACKING OF AIRCRAFT Extensive damage and injury result from careless and improper jacking procedures. Only general jacking procedures and precautions will be discussed as the procedure and precautions vary for different types of aircraft. PRECAUTIONS AND PROCEDURE a)Prior to use, inspect the lifting capacity, proper functioning of the safety locks, condition of the pins and general serviceability of the jacking equipment. b)Consult the manufacturer's maintenance manual for the location of the jacking points. c)Consult the manufacturer's manuals for the correct jacking configuration, i.e. ballast weight added, stress panels fitted, etc. d)Before raising the aircraft on jacks, all work stands and other equipment should be removed from under and/or near the aircraft. e)The aircraft to be jacked must be located in a level position, well protected from the wind If possible a hanger with closed doors should be utilised for the jacking procedure. f)The correct jack pad assembly as prescribed in the manufacturer manual should be used. g)Tripod jacks of the appropriate size for the aircraft to be jacked should be placed under the aircraft jacking points, and perfectly centered to prevent them from cocking when the aircraft is raised. h)The legs of the jacks should not interfere with any operation during and after the jacking procedure. Extend the jacks until they contact the jack pads. Do a final alignment check of the jacks and jacking pads before the aircraft is further raised. I))An operator should be stationed at each jack to operate the jacks simultaneously to keep the aircraft as level as possible and avoid overloading any of the jacks. The crew chief normally standing in front of the aircraft will give instructions to the jack operators. j)Follow the jacking with the safety device to prevent damage in event of a jack failure. k)Any cradles or necessary supports should be placed under the fuselage or wings at the earliest possible time. l)Before lowering the aircraft, ensure all work stands, equipment and personnel are clear of the aircraft. The landing gear must be locked in the down position with all the required ground locking devices correctly installed. JACKING ONE WHEEL OF AN AIRCRAFT a)Consult the manufacturer's manual for the correct procedure and equipment. b)Before raising the wheel, the remaining wheels must be chocked fore and aft to prevent movement of the aircraft. c)Raise the wheel only high enough to clear the tarmac. FIRE INTRODUCTION TYPES OF FIRES TYPE OF FIRE AND ITS EXTINGUISHING AGENT AIRCRAFT FIRE EXTINGUISHERS EXTINGUISHING AGENTS NOT AIRCRAFT USE FIRE FIGHTING APPLIANCES HOUSEKEEPING BRAKE FIRES INTRODUCTION Three items are required to keep a fire burning: FUEL that will in the presence of heat combine with oxygen to release more heat. HEAT can be considered the catalyst that accelerates the combination of fuel and Oxygen, thereby releasing more heat OXYGEN the element that combines chemically with another substance through the process of oxidation. Rapid oxidation accompanied by a noticeable release of heat and light is called combustion or buming. Removal of any one of the three substances will extinguish the fire. TYPES OF FIRE Class A fires: ordinary combustible materials such as wood, cloth, paper, upholstery,upholstery,material,etc Class B fires;flammable petroleum products or other flammable and combustible liquids. grease, solvents, paints, etc. Class C fires; energised electrical equipment where electrical, non-conductivity of the extinguishing media is of importance. In cases where electrical equipment is de-energised, extinguishers suitable for use on Class A and class B fires may be used Class D fires; flammable metals. Generally caused by other class fires for example, magnesium in the workshop or in aircraft wheels and brakes. Any of the fires can occur during aircraft maintenance. There is a particular type of extinguisher that is most effective for each type of fire. TYPES OF FIRE AND EXTINGUISHING AGENT CLASS A B D MATERIAL Wood, cloth, paper, etc. Flammable petroleum products Electrical wiring, equipment or current Flammable metals EXTINGUISHING AGENT Water and water types which cool the fuel below combustion temperatures Carbon dioxide (CO), halogenated hydrocarbons (HALON) and dry chemicals. All replace the oxygen in the air thereby making combustion impossible. Foam is effective when used in large quantities. Water is ineffective and will cause the fire to spread. Carbon dioxide (CO) which displaces the oxygen making combustion improbable. The equipment must be fitted with a non-metallic discharge hom approved for use on electrical Halogenated hydrocarbon (HALON) reacts chemically with the flame to extinguish the fire. Dry chemicals are effective but have the disadvantage of contaminating the local area. fires. Dry powder prevents oxidation and the resulting flame. Application may be from an extinguisher, scoop or shovel. Water must never be used on a metal fire. Water will cause the fire to burn more violently and can cause explosions. AIRCRAFT FIRE EXTINGUISHERS Airbome fixed power plant and airframe, detection and extinguishing systems are designed and installed by the manufacturer in compliance with acceptable regulations like the FAA, CAA and DCA or Mil Spec. The requirement for portable fire extinguishers installed in crew and passenger compartment's states: -the extinguisher must be approved; - must be appropriate for the kind of fire likely to occur, and; - must minimise the hazard of toxic gasses. EXTINGUISHING AGENTS NOT RECOMMENDED FOR AIRCRAFT USE DRY CHEMICAL EXTINGUISHERS Though very effective on Class A and Class B fires, they leave a residual dust or powder. This obstructs vision, is difficult to clean up and causes damage to electrical equipment. CARBON TETRACHLORIDE (HALON 104) It is no longer approved as a fire extinguisher agent. It is toxic and produces a poisonous gas when in contact with hot metals. SODA ACID AND FOAM These are toxic to a degree and can be corrosive to adjacent materials. METHYL BROMIDE (HALON 1001) Is more toxic than CO and cannot be used in confined areas. It is additionally very corrosive to aluminium alloy, magnesium and zinc. CHLOROBROMOMETHANE (HALON 1011) Although an effective extinguishing agent, it is toxic. FIRE FIGHTING APPLIANCES Though most fire extinguishers work on the same principle of a strike button to be activated, it local fire fighting equipment. Also be aware of the location of the fire extinguishers, fire alan points, fire alarm sound and the emergency exits in your working area. HOUSEKEEPING FIRE PREVENTION s are reduced by efficient servicing methods and observance of the fire ed in the workshons and sevicing bavs All orecautions must be backed by the ability to mínimise the effects of a fire by prompt use of first aid fire fighting equipment Aircraft fire hazards FLAMMABLE LIQUIDS Aircraft fuels, lubricants and hydraulic oils are fluids that are easily ignited. Any spillage leakage must be investigated and cleaned up immediately. During aircrat rerueg defuelling there is a particularly high risk of fire and all precautions should OXYGEN SYSTEMS Oxygen systems e normally stored in high pressure cylinders in aircraft. Any leakage from dd to the fero this system wi rocity of the fire. Oil and greases must not be used on oxygen equipment as s could cause spontaneous combustion resulting in a fire. The regulations regarding the storage, installation and servicing of oxygen systems must be strictly observed. CLEANING MATERIALS Waste fuel, oils and lubricants from drip trays and de-greasing tanks must not be allowed to accumulate in hangers or workshops. Any rags impregnated with these fluids must be kept in a metal container fitted with a lid. NAKED LIGHTS AND OTHER HEAT SOURCES Naked lights are a source of heat and must be avoided near aircraft. Only use recognised sealed light units near aircraft. Smoking is not permitted in the vicinity of aircraft, hangers, fuel installations or explosives' areas. Avoid carrying matches and cigarette lighters when working on aircraft. AIRCRAFT FIRE EXTINGUISHING PROCEDURE Before starting to work on an aircraft type, always refer to the applicable aircraft manuals for the correct fire fighting procedures. This will ensure the correct fire extinguishing equipment and procedure is utilised in event of an emergency. BRAKE FIRES When aircraft brakes have been applied excessively during ground maneuvering, overheating could occur. Care must be taken when approaching such aircraft, as a danger of fire and/or possible explosion exists. This danger prevails for the time required for the brake assemblies too cool. It is advisable to approach aircraft wheels from a forward and/or aft direction only as long as overheated brake assemblies are suspected. Severe fires must be treated with dry powder extinguishers only. Normally the hot brake assembly should be observed from a safe distance and permitted to cool without treatment. EVACUATION INTRODUCTION EVACUATION PROCEDURE HOUSEKEEPING INTRODUCTION When any danger to personnel, like a fire or fire hazard, bomb threat or any other emergency is identified, an evacuation program can be implemented. When any emergency is identified, notify your superior or safety representative and the emergency services. Activate the emergency plan and proceed with the evacuation. GENERAL EVACUATION PROCEDURES a)On hearing the alarm evacuate your place of work immediately. If time permits, close office doors and windows, switch off fans and/or heaters, and remove plugs from wall sockets. b)Walk quickly, do not run c)Use the shortest and safest route to the exits and assembly points. d)Report your presence to the group controller at the assembly point. e)Visitors to your work area must accompany you to the assembly point f)Only return to your workplace once permission to do so is granted. HOUSEKEEPING a)Be aware of the location of the assembly point and the route or routes to the assembly point. b)Report any suspect objects immediately to your superior or safety representative c)Report any emergency condition like fire, gas leaking, etc. to your superior or safety representative TECHNICAL HANDTOOLS POWERED TOOLS LEAD LIGHTS EARTH RETURN PROTECTION GRINDING MACHINES ELECTRICAL WELDING RADIOGRAPHY AND X-RAYS LASER, RADAR AND RADIO TRANSMITTERS HANGER DOORS SAFETY COLOURS LIFTING EQUIPMENT SERVICING PLATFORMS HANDTOOLS Arrange the tools to be readily at hand and easily checked. Use a shadow board or similar system to safeguard tools, and help with the daily tool check Files Never use a file without a sound tight fitting handle Hammers Loose fitting hammer heads are liable to fly off and cause injury or damage Screwdrivers Always use the correct size and shape for the screw. Check that the blade tip is in a good condition. For electrical work use a screwdriver with an insulated handle. Do not carry screwdrivers or similar sharp pointed tools in your pockets. Punches Punches with mushroom' heads are dangerous. Keep the head ground or filed to its original shape. Always use the correct size spanner for any nut or bolt to be tightened. Ring and socket spanners are to less likely to slip off the nut or bolt and are to be preferred to common open-ended spanners. Wherever possible PULL rather than push a spanner. Spanners Always use the correct size spanner for any nut or bolt to be tightened. Ring and socket spanners are to less likely to slip off the nut or bolt and are to be preferred to common open-ended spanners. Wherever possible PULL rather than push a spanner. Pliers When using pliers for clipping wire, use it so that the snipped wire is deflected towards the ground or floor. Never use pliers to tighten or slacken bolts, nuts or screws. POWERED TOOLS Electrical and pneumatic powered tools are designed to be powerful and once started cannot be stopped immediately. Before using powered tools ensure all appropriate guards and fences are securely installed. Ensure protective clothing is correctly worn and that no part of the clothing or your body comes in contact with the moving parts of the tools. Always switch OFF and disconnect powered tools not in use. ELECTRICAL POWERED TOOLS a)Before use of any electrical powered tool, inspect the connecting cable for damage. b)Before use inspects the earthed 3 pin plug for security. c)On a cable run allows sufficient slack to avoid any strain on the cable connections.Avoid any kinks in the cable run. d)Take care that the cable is not trodden on or chafed by sharp edges. e)Ensure that the Cable is not lying in oil or liquid. f)Always ensures that the tools and/or equipment and the wall plug are switched off before the plug is connected or disconnected from the wall plug. PNEUMATIC POWERED TOOLS a)Tools powered by compressed air can be extremely dangerous if it is misused or abused. b)Air pressure lines must be handled with care and connecting nozzles must never be pointed towards a person. Air blasts can penetrate clothing and cause injury. c)It is not allowed to clean workbenches with compressed air. d)Ensure that the equipment is OFF before the pressure lines is connected or disconnected from the wall plug. LEAD LIGHTS FLAME PROOF LAMPS Only flame proof lamps may be used in or near flammable areas, or if flammable conditions are possible. Fuel, dope, paint, or flammable gasses may all react or combust spontaneously with open or non-flame proof lamps. Ensure that all seals and insulating compounds are maintained in good condition. NON-FLAME PROOF LAMPS Non-flame proof lamps are quite safe for general use. These lamps are NOT safe in flammable conditions like paint spraying or aircraft refueling and defuelling or where the presence of explosive gasses is possible. EARTH RETURN PROTECTION The earth lead provides a path for current to flow under earth fault conditions. The earth path must have sufficiently low impedance to limit voltage rise and permit ample current to flow. This will ensure rapid operation of the over-current device in event of an earth fault. If the over-current device operates slowly or not at all, the result can be a combination of electrocution, fire or destruction of equipment. ELECTRICAL WELDING a)Ensure all leads, return, earth cables and couplings are serviceable and correctly attached. b)Ensure the working area is dry and free from obstructions. c)Ensure adequate lighting and ventilation are available. d)Correct protective clothing should be worn. Shields providing protection against arc flash and droppings should be provided and used. f)Take care that cables do not drag across hot plates or welding. Also prevent from touching hot plates or welding. GRINDING MACHINES Do not grind soft material or non-ferrous metals. Only ferrous type metals are to be ground. Do not change the structure of the wheel. Check and adjust the tool rest so that the work piece will not jam. Be aware of the power switch location. Always wear eye protection when working on a grinding machine. Clean out residual grinding material as some metals pose a fire hazard. RADIOGRAPHY OR X-RAYS Radiography is a non destructive testing (NDT) technique for detecting cracks and/or defects without dismantling the aircraft. Radiography is potentially very dangerous and is consequently only performed by a trained team of personnel. An overexposure to X-rays and gamma rays can cause leukemia and possibly death. The area round an aircraft being radio graphed is therefore roped off and warning signs are displayed at points round the bather. LASER, RADAR AND RADIO TRANSMISSIONS Some high powered radio transmissions and radar emissions can cause 'radio burns' and internal injury. In addition to health hazards, these emissions could cause fires by igniting vapours present during fuelling operations and spray painting. All tests should be conducted outside hanger confines and adequate warning be given verbally and by means of warning signs. TYPES OF EMISSIONS Laser Radar -high power narrow beam from the laser assembly. -high power microwave radiation from front facing radar. HF radio transmissions -high power high frequency radio communication transmissions. HANGERDOORS The electrically operated doors are a danger to personnel and equipment if abused during operation. The great mass makes it hard to stop once the doors are in motion. A yellow line on the floor alongside the doors demarcates the clear zone. This zone should remain clear of all equipment, cables, stands or aircraft. OPERATING HANGER DOORS a)Ensure through inspection that the area on both sides of the doors, including the area to be moved into, is clear of all foreign objects (FOD). Also ensure the running track is clear of FOD. b)Always walk with the door while it is moving checking all clearances. Riding on the doors is strictly prohibited. c)Adhere to the door moving bell warning and remain clear of the moving door. SAFETY COLOURS RED Colour coding assists in identifying potential hazardous areas as well as safe areas and equipment. Red is the basic colour for: Fire protection equipment and apparatus Stop buttons and emergency stop buttons ORANGE Orange is the basic colour for designating danger and for parts of equipment that might cut, crush, electrocute or otherwise injure personnel. NOTE: Electrical motors are not painted orange. YELLOW Yellow designates all caution areas such as: 'striking against', 'stumbling', 'falling', etc. Solid yellow and black lines will attract the attention the best in the particular area. GREEN Green designates safety. Evacuation routes and emergency routes, first aid equipment other than fire fighting equipment will be painted in green. LIFTING EQUIPMENT Equipment like engines or mainpianes too heavy to be lifted manually is normally lifted with cranes or hoists. The equipment is normally attached to the crane or hoist with a sling assembly. Each sling has a test certificate and a brass tag for identification and the Safe Working Load (SWL). SWL is the maximum weight that can be lifted safely by the sling assembly. Although routine inspections are carried out on the slings, a "before use" safety visual inspection must be carried out by qualified personnel. GENERAL PRECAUTIONS FOR CRANES AND HOISTS a)Ensure the load is within the SWL of both the crane and sling assembly. b)Keep clear of any suspended load. Use a rope to steady high lifting load. c)Avoid walking or working under the suspended load at all times. d)Never leave a suspended load unattended SERVICING PLATFORMS The platform is normally completely mobile having solid, rubber-tired casting wheels fitted to each supporting leg. Though tools aren't to be stored on the platform, a guard should be fitted to prevent them from dropping off. If a platform is higher than 2 meters a safety rail must be fitted. When positioning platforms, care must be taken that no movable aircraft parts like the control surfaces or undercarriage is fouled. Once work is completed the stand or platform must be stored clear of the aircraft in the designated storage area. YOU INTRODUCTION CLEANLINESS PERSONAL PREPARATION INTRODUCTION You are the biggest safety asset in the company. Accidents are more often caused by your own carelessness or disregard for workshop safety rules. For your own safety be aware and familiar with the whereabouts of the telephone, First Aid Box, power switches, fire alarm (warning point and sound), fire extinguisher, evacuation routes Sand emergency exits. CLEANLINESS Skin irritation can be caused by certain types of hydraulic fluids, fuel, oil or other substances. Use a good barrier cream and the correct protective clothing to prevent the onset of any skin irritation or injury. PERSONAL PREPARATION DRESS Overalls are provided for protection and clean overalls must always be worn at work. Where prescribed by area rules, additional protective gear like; goggles, masks, breathing apparatus, special boots or shoes, gauntlets, suits, ear defenders, etc. must be wom. These devices are provided for your protection, use them. A little inconvenience is a small price to pay to avoid permanent loss of a member or sense. THE JOB OR TASK Always be sure you know what the job entails. Be aware and sure of the safety precautions and procedures to be observed. If in doubt ask and/or check the relevant documentation!