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By Gammon Technical Products, Inc. Keep Them Flying!. Aviation Fuel Quality Control. An Overview of Fuel Quality Control Guidelines and Test Equipment. ATA-103 (Airlines) NFPA-407 (Fire Safety) Your Oil Company Airline Specific Policy ASTM Manual 5 FAA. Standards. - PowerPoint PPT Presentation
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Aviation Fuel Quality Control
By Gammon Technical Products, Inc.
An Overview of Fuel Quality Control Guidelines and Test Equipment
Keep Them Flying!
Standards
ATA-103 (Airlines)NFPA-407 (Fire Safety)
Your Oil CompanyAirline Specific Policy
ASTM Manual 5FAA
Even Professionals Make Mistakes
The Old Way
DART
Reed Fuller
What Do You Do When You Have A QC Problem?
Eliminate Any Risks Fix the Problem Educate Your People
But everybody will avoid calling the Associated Press, and that is why you rarelyhear of problems at other locations, but believe it, there are problems!
What is Our #1 Job?
To put the correct clean, dry, unadulterated fuel into the correct aircraft
To do the job safely To prevent fire To prevent spills To follow the QC program and make sure others
do also To properly operate and maintain the
equipment To always be on the lookout for potential
problems
Utilize the Latest Equipment
Rampmaster .2
Velco
n V
F-1
Grounding Cable
Truck Internal Valves
NFPA 407 Precheck even if Scully is used Make sure emergency shutoff
closes valve Do not use truck unless internal
valve operates properly
Quality Control is: Having the Correct Equipment Tests and Procedures - To ATA-103,ASTM API
and Other Standards A Pain in the Butt Making Sure You Don’t Damage the Aircraft Not a Profit Center An Indispensable Policy That Must Permeate
Your Entire Company From The Top to the Bottom Covering Personnel, Environmental and Flight Safety
MOST IMPORTANTLY It must be followed!
Make sure the paperwork matches the aircraft?
Do You Check Your People to Make SureThe Paperwork System is Being Followed?
Worn Equipment Is a Sign Of Use!
LOOKING FOR CHANGES
The Key to Quality Control is to take note of anything out of the ordinary. Even if the results are still within “acceptable”
limits, a sudden change to any characteristic or the performance of any
piece of equipment may indicate a serious problem
Testing and Sampling is Meant to Find Little Problems Before
They Become Big Ones!
Changes To Look For Any and All Test Results -Even if the Results are “Acceptable” “Too Good” or “Too Consistent” Results (Pencil whipping) Outside of Prefilter Elements Inside of Coalescer Elements Strainers Nozzle - Coffee grounds and metal shreds???? Differential Pressure / Flow Rate White Buckets - All Aspects, color, odor, haze, “lace”, water,
etc. Membrane Test Time Paperwork Labor Times for Inspection Employees Equipment Appearance DID YOU MAKE A CHANGE? - Nozzle pressure changes with hose
length or size!
True?
A check is in the mail
I’ll love you in the morning
We only use dedicated tractor trailers
Our pipeline always makes perfect “cuts”
Our equipment never breaks down
Our membranes are always A-0
We never see any differential pressure
We never have any water in our fuel
In 20 years we’ve never had a problem
====up until now===
Receiving Fuel
The Most Overlooked Aspect of Fuel Quality Control
Oh, you're the picky guys. (Actually said by a terminal employee.)
Jet Fuel, Avgas, same thing, right (Actually said by a transport truck driver.)
One Rejected Load Was Actually Delivered to the Next Door FBO
Pumping Fuel Into Storage
Stick Tank to Make Sure You Have Room
Sump any Water From Tank and Filter FIRST
Monitor Differential Pressure on Filter
Sample the Fuel With MiniMonitor or Millipore Tester
Check the Filter Sump after Unloading
Check Tank Volume Net Gallons will
vary! Record the Data
White Bucket Test Color - Jet Consistent and NOT Pink! Odor Haze / Cloudiness Liquid water in the bottom of the bucket Spill coffee, food coloring or other water based
liquid in to be sure the bucket isn’t pure water Particles or Debris Filmy or lace- like floating material Anything else different from the usual Fuel Should be Clear and Bright - No Visible
Contamination
CLOUDY FUEL OBSERVED WHILE PERFORMING A WHITE PORCELAIN
BUCKET TEST INDICATES ENTRAINED WATER, SURFACTANT OR BOTH
CLEAR WHITE BUCKET SAMPLE INDICATING NO WATER
OR PARTICULATES. USE ANY COIN.
A Jar Makes An Inexpensive Test Device
For Detecting Haze
Is There Water In The Bottom?
Spill In a Little Coffee or Food Coloring
And Water is More Distinct
Haze is Free Water
0.75”, 2” and 3” bottles with 100PPM of water
Accurate Hydrometer Readings(Mercury Issue)
Spin the hydrometer gently
Do not allow it to touch the jar
Keep it clean
A Centering Device
Can Make
Correct Readings
Easier
When You Raise Your View To Be Level With The Surface This Will Indicate API
43.5
Indicated API 40.3
Using A Spill-Over Type
Hydrometer Jar
1. Align measured fuel temperature against measured API
If You Read 43.5 at 81.6 degrees F 2. Read corrected API at 60 F mark
3. Result is API gravity at 60 F of 41.65
“Normal”Contaminants in Aviation Fuels
Dirt Dust (From Tank
Vents) Rust Water (Lots of
Water!) Surfactants
Pieces of Burst Filters Tank Lining Paint
Chips Other fuels Microorganisms Rubber from failed
hose
And MUCH More!
Real Contamination in Aviation Fuels
Lavatory “Blue Fluid”
Fuel Oil Fertilizer Outlet Prist Can
Tubes Lizards Dead Birds Sand Metal Shavings
Transmission Fluid Insects Caustic Soda Gloves Rags Eyeglasses Fish Bolts / Other
Hardware
What is the Most Common Way Gross Water Gets into Aircraft?
Through the Vent or Roof of the Refueler Truck
Keep Rain Drains Clear
Any Leak Can Let Rainwater Into The TankWhen The Vent Opens Any Standing Water Will Enter the Tank!
The Drain LinesShould Be Transparent Plastic So You Can Inspect For Debris
Water in Aviation Fuels
DISSOLVED WATER Like Humidity in Air Cannot be
Measured With Field Equipment
Cannot be Removed by Filtration
1 PPM per Degree Fahrenheit
UNDISSOLVED WATER Free Water Like Fog In Tank Bottoms Slugs Can be Removed By
Filtration Will Settle From Fuel
Aquarius Additive – 2 to 5 years awayWater - Bio - CI/LI – FSII/Prist
What Is A Part Per Million?1 Gallon Per Million Gallons
1/10,000 of 1 percent
A Properly Operating Filter Separator or Monitor Will Remove Water Down to NO
MORE THAN 5 PPM!
Detecting Free Water In Fuel
VISUAL - Haze is Visible at 30 ppm Velcon Hydrokit - Water Detector 15 or 30 ppm Shell Water - Detector 15 or 30 ppm Metrocator - Spotted Paper Indication AquaGlo Water Detector - An Instrument For
Measuring Water Water Finding Paste? NO! Only For Water Level
In A Tank Bottom Water Probe? Only for detecting water in sumps
The Aqua-Glo Water Detector KitManufactured Under License From Exxon
As Required by ASTM and API for Measuring Free Water
A Free Video On Calibration and Use is Available - Just Call 800-524-0287
MICROBIAL CONTAMINATION
FOUND IN THE AIR AS SPORES
FOUND MAINLY IN WATER
SIDE OF TANK WALL
WATER IN TANK BIRD BATHS
IT CAN TRAVEL
FILTRATION EQUIPMENT
AIRCRAFT FUEL TANKS
REMEDY/BIOCIDES
An 87 or 9 Series Coalescer Element Will Remove
About 99% of Particles over 1/3 Micron
Dirt In Aviation Fuel
Bonding And Grounding Hose Assembly
MiniMonitor Particulate Detector
to ASTM D2276
What is Bonding and Grounding?
Bonding is connecting two parts
Grounding is connecting those parts to earth
The purpose of bonding and/or grounding is to neutralize sparks between items before and during operations
MOST IMPORTANT Bonding aircraft during refuelingBonding and grounding ALLALL other operations
NFPA-407 2001 Actually forbids grounding of refueler trucks in direct refueling
F-15 Hangar Problem Auto-Fire
suppression shut off after inadvertent release
Explosion during defueling in open air from wing tank
They couldn’t be convinced that bonding was necessary
They agree now
A Ball Valve Will Aid in Operation In High Pressurized Systems
Our New QD Will NOT Spray Fuel!
Turn Valve to TEST Position to Flow Fuel Through the Plastic Monitor
Flow
Ground to Pipe, NOT Fitting as Shown!
Flow 1 or 3 Gallons of Fuel Into the Bucket
Ask Your Fuel Supplier or Airline How Much
Maintain The Bond to the Bucket!
Draw Excess Fuel From Monitor - Observe the Membrane for Unusual Color
Remove the Membrane - Dispose of the Thicker Backup Pad
Undated Books or Books Dated 1981 Or Older Are No Longer Approved Under ASTM
The ATA Standard Color Chart With Particulate Chart
Evaluation Of Membranes
GTP Rule of Thumb
Dry Color Should Be Less Than a “3”. A 2 Is Cause For Concern
If You See a Membrane Different From Your Usual Scale
(For Example, You Usually Get an “A-2” and Suddenly Get a G-2) This May Indicate A Serious Contamination Problem
If You Get a Sudden Dark Membrane, Run a Test Before and After the Filter. Look For a Change.
You Can Run The Test With Two Membranes. If The Bottom Membrane Has Color, This is “Color Bodies”, Which May Not Be a Problem
Replacement Plastic Monitors
Replacement Membranes
Save Money
Reload Your Old Plastic Monitors
Properly Label ALL Equipment Especially Emergency Controls
We have a free Test Procedure and Certificate
When The Test Valve Is Operated, The Piston Should Move Smoothly To The Bottom Of the Scale.
If It Moves Smoothly But Slowly, You May Need A New Filter.
If It Moves In Jumps, Or Does Not Move To The Bottom Of The Scale, Clean The Glass And Piston With Scotch-Brite
Return The Valve To The Normal Position, Stop Flow. The Piston Should Return To Zero. If Not, Clean The Tube And Piston, If This Does Not Solve The Problem, Replace The Spring
This Pushbutton Tester Is Simple, Inexpensive And Includes A Pressure Relief Valve
Flushing New Fuel Hoses
Repeated soak and dispose Once fluid is clear Minimum 500 gallon recirculation
flush
The interior of a hose is called the tube. This tube must be conditioned. No brand of hose is exempt. If a Salesman Says His Hose Doesn’t Need Flushing THROW HIM OUT!
Testing Your Equipment Make Sure the Water Detector Works Make Sure the Deadman Works Make Sure the Emergency Stop Works Makes Sure the “Nozzle Pressure” Gauge is Accurate at
Both No Flow and Full Flow Make Sure The Fire Extinguisher is OK Inspect the Hose Exterior for Wear Check For Leaks Check the Grounding/Bonding Reel TEST DRIVE the vehicle to test interlocks
3-Lug Adapters and Nozzles
Check Aircraft for missing lugs Check Aircraft for excessive wear Includes: Slots, Lugs and Seal Area Check Nozzle for proper fit, proper
condition Look for leakage or movement Look for slippage of hose at ferrule (API-
1529 Requirement for paint mark!)
Filter Separators - EI/IP/API-1581
Vessel/Filter Filter element combination MUST meet new 1581 5th Edition unless excepted
New Requirement – Flat Bottom vessels must have slope unless excepted
Corrected DP – How on Hydrant System? Gammon FR Meter coming soon (Max flow, Pipe size, orifice size)
What is Coming in the Future!
BP Kerostat 8118 = to Stadis 450 (Almost there)
Aquarius (777 +others approval testing needed)
Synthetic Jet Blend 50:50 (issues)
Bio Jet Fuel (cost/issues)
Bio Contaminant Detection 100 ppm Pipeline)
FSII reduction 25% eventually to 400 ppm
EndThank You
Gammon Technical Products, Inc
2013