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Safety Guidelines 1

SECTION 1

SAFETY GUIDELINES

All maintenance and repair work carried out on Fluid Transfer International refuelling
vehicles, units and ancillary equipment should only be undertaken by fully trained
professional mechanics and engineers. Such people should be fully trained in safe
working practices. A moment’s lack of attention or failure to observe elementary
precautions can result in an accident. There is always a new way of having an accident,
do not be the one who discovers it.

Below is an elementary list of possible dangers, it is not comprehensive but it is intended


to make one aware of the basic risks and to encourage a safety first approach to all work
carried out on your Fluid Transfer International equipment.

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Workshop Safety, Maintenance and Repair

Abrasive Wheels, Grinders, Grinding Wheels and Wire Wheels

Only those persons trained in the use of abrasive wheels should use them.

Where abrasive wheels are used appropriate protective clothing and goggles must
be worn.

Asbestos

On most modern equipment the use of asbestos has been replaced by alternative
materials and Fluid Transfer Limited do there utmost to use components fitted with
these materials. However asbestos my still be present in certain friction, insulation
and sealing items. Extreme care must be taken to avoid breathing in the dust of
such items, as it is hazardous to health.

Batteries and Battery Chargers

Warning: During and after charging batteries give off hydrogen, an easily ignited and
explosive gas.

Battery chargers should be switched off before connecting or disconnecting batteries.

All crocodile clips and battery connections must be kept clean and free from
corrosion

If the battery charger is not of the safety isolating type, one pole of the charging
circuit should be earthed and marked to prevent a short circuit when the charger is
used with a battery on which a different pole is earthed.

Avoid metallic objects coming into contact with battery terminals and causing a short-
circuit. Persons dealing with batteries or their charging should not wear items of
jewellery that could come into contact with battery terminals.

All persons dealing with batteries, battery charging or acid should wear protective
clothing and goggles.

Access to eyewash and running water should be readily available.

Battery acid should be stored safely and clearly marked.

Cleaning Vehicles.

Some cleaning agents contain harmful or toxic and flammable solvents. Direct skin
and eye contact with such solvents is harmful and should be avoided. They can also
present a fire risk. Take great care in their use.

Attempt to use only water based cleaning agents were ever possible, i.e. soap
solution.

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Compressed Air Equipment

Compressed air and related equipment should always be inspected and maintained
regularly.

Care must be taken to avoid accidental 'injection' accidents when using compressed
air equipment. Injuries, which may occasionally be fatal, can be caused by deliberate
or accidental injection of compressed air either through the skin or into body orifices.
If accidental injection injuries occur medical advice must be sought immediately.

Do not leave trailing airlines across gangways or access areas.

Draining of Recovery Tanks, Filters and Pipework

Extreme care must be taken when draining to avoid spillage and minimise vapour
levels.

Park vehicle on level ground and determine how much product is required to be
drained and select container(s) with sufficient capacity. Never collect product in
containers that can be knocked over.

Do not drain by methods that could result in uncontrolled spillage.

Label and store the recovered product safely away from heat and ignition sources
labelled ‘Contaminated Aviation Fuel’.

Do not add drained product to the waste oil tank.

Ensure good ventilation if draining inside a closed building.

Eliminate ignition sources by:

Ensuring there is no smoking within the building.

Turn off the battery master switch and allow engine parts to cool.

Remove any equipment not designed for use in a flammable atmosphere.

Electrically bond and earth the fuel retriever and vehicle to minimise the build up of
static electricity.

Dust

Where there is a risk of inhalation, or damage to the eyes, due to exposure to dust or
particles, a suitable dust mask and goggles should be worn.

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Electrical Safety

All electrical appliances should be inspected and maintained regularly. Any electrical
equipment that is condemned as faulty should be removed from use immediately and
labelled.

Electrical repairs should only be carried out by a qualified or competent electrician.

Note: Low voltage and insulated leadlamps offer no protection against the risk of
igniting petrol or other flammable vapours, and must not be used where such
vapours may accumulate.

Before connecting electrical equipment to the mains supply visually check, that the
lead, plug and socket are undamaged.

Electrical leads should not be trailed across walkways.

Equipment for Personal Protection

The following equipment for personal protection should be worn when carrying out
certain tasks:

Safety shoes: At all time when working on your equipment, both inside and outside
the workshop.

Protective overalls: At all time when working on your equipment, both inside and
outside the workshop.

Hard hat: When ever work is being carried out overhead or there is a danger from
falling objects.

Safety goggles: When working on or with machinery of all kinds, or when working
with someone working with machinery. Also when there is a danger from flying
objects or dust particles.

Ear defenders: When working in a noisy environment, especially on the airfield.

Dust masks: When working in dusty or lightly contaminated environments (full-face,


air fed respiratory masks should be worn in more contaminated conditions).

Rubber gloves: When working with hazardous substances, i.e. battery acid or paint.

Exhaust Emissions

Warning: Exhaust fumes from internal combustion engines are toxic, and may reach
harmful concentrations particularly from 'cold' engines or those being constantly
started and stopped. All persons running vehicle engines in the confinement of the
workshop should use an exhaust extraction system.

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Fire

Petrol (gasoline), diesel, aviation fuel, even lubricating oil are highly flammable
substances and the risk of fire is always present, especially in hot climates. Never
smoke or have a naked flame in the area. It is advisable not to carry matches or a
cigarette lighter while working on your equipment.

Avoid sparks from electrical short-circuits, the contacting of two metallic surface with
each other, the careless use of tools or the build up of static electricity.

Always disconnect the battery earth (ground) terminal when working on a vehicle or
equipment fitted with a battery.

Never allow fuel, including the vehicle’s propellant fuel to spill on to hot surfaces.

Spillage’s should be cleaned up immediately. If using rags, dispose of them straight


away in a closed container. Do not soak up spillage’s with sawdust, always use one
of the proprietary non-flammable granular agents.

Always keep a fire extinguisher to hand while working on your equipment, never
attempt to extinguish a fuel or electrical fire with water.

Oxyacetylene cylinders present an extreme risk of explosion in the event of fire and
no attempt should be made to approach or move them.

First Aid

Adequate numbers of staff should be trained as first aiders, and clearly marked First
Aid boxes should be provided. The contents of each first aid box should be checked
on a regular basis to ensure that it remains suitably stocked.

If the injury is serious a doctor should be summoned and/or the casualty should be
taken to hospital.

Flammable Liquid and Gas Storage and Handling

Petroleum spirit and petrol/diesel mixed fuel should to be stored in clearly defined,
designated storage area with warning signs.

Flammable liquids should be stored and transported in sealed metal containers


clearly marked with the contents.

Flammable liquids should be transfered firstly by means of a hand pump or secondly


by using funnels and there must be no source of ignition within 8 metres of the
operation

The lids of these container should be replaced immediately.

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Fork Lift Trucks

No one should operate a fork lift truck unless they have been trained and authorised
to do so.

Fork lift trucks should regularly inspected and serviced.

When not in use the truck should be parked in a safe area with the fork arms lowered
to the ground with the parking brake applied and the engine switched off.

Always travel with the fork arms as low as possible and check there is sufficient
clearance overhead before raising a load.

Never lift a person on the forks or allow people to walk underneath a load.

Hand Tools & General Workshop Equipment

Hand tools should be well maintained and fit for the purpose. Damaged or worn tools
may slip and cause injury.

Hand tools, including items of plant and machinery should only be used for the
purpose for
which they were designed.

Only competent persons should operate workshop machines or equipment.

All flywheels, belts, pulleys, shafts and other moving machine parts, which may
cause injury, should be completely guarded so as to prevent access to any
dangerous part.

Suitable eye protection should be worn while operating bench mounted drills,
presses, grinding and wire brushing machines.

Adequate provision and use should be made of work-piece clamping on drilling


machines.

Hazardous Substances

Absorption of substances can occur through ingestion, inhalation, inoculation and


directly through the skin, therefore appropriate control measures should be in place
to reduce the risk of contamination.

Persons contaminated with, or in some other way exposed to hazardous materials,


must seek immediate medical aid.

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Ladders

All ladders used in the Workshops should be inspected regularly they should not be
used if they show signs of damage or defect.

Ladders should be used as a means of access only, and not as a working platform.

Ladders should be secured if access height exceeds 3 metres and should be placed
on a firm flat surface.

Lifting Equipment

Chains, ropes, hoists, cranes and lifts, including recovery vehicle equipment should
be thoroughly examined every regularly (in many countries this is statutory and
certification is required).

Vehicles should only be lifted using jacks whilst on a level undamaged floor.

All lifting equipment should only be used within their safe lifting weight
recommendations.

Jacks should only be used for lifting a vehicle. Axle stands positioned on a firm level
floor should be used to support a vehicle if work is to be carried out beneath it.

Under no circumstance should anyone go beneath a vehicle supported only by


a jack.

Manual Handling

Manual handling injuries constitute a major source of injuries especially to one’s


back.

Avoid lifting or moving heavy objects, use lifting aids wherever possible.

Noise

Wherever possible measures should be taken to contain noise within enclosed


areas.

Where this cannot be achieved ear protection should be worn.

Paint Spraying

Spray paint is highly toxic and can damage lungs, skin and eyes.

Paint spraying should only be carried out in the paint spray booths equipped with full
exhaust ventilation and filtration.

Personnel carrying out spray paint should be fully trained and competent.

When mixing and spraying a full-face, air fed respiratory mask should be worn.

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Smoking

Smoking should not be allowed anywhere around your refuelling equipment or on the
airfield (in most countries this is statutory).

Steam and Water Pressure Cleaners

Care must be taken when using steam/water cleaners as fatal accidents can be
caused when the equipment becomes live due to electrical faults.

Only trained and competent operators should use steam/water pressure cleaners.

Eye protection and dust mask should be worn to prevent injury from dust and debris
disturbed by the cleaning action.

Vehicle Inspection Pits

Vapours from petrol, aviation fuel and solvents are heavier than air and can
accumulate in pits and produce flammable and toxic atmosphere. Take great care
when using equipment that produce sparks (electrical, grinding, cutting or welding.

Never leave rags or absorbent granules in pits that can collect spilt fuel and become
a fire hazard.

Waste Disposal

Waste products especially those associated with the aviation refuelling industry can
have a detrimental effect on the environment. The disposal of all waste i.e. tyres,
batteries, scrap metal, asbestos, aviation fuel, vehicle fuel etc should be carried out
in the correct manor as detailed under current Environmental Legislation or
International Protocols.

Long periods of exposure to hazardous waste products can cause dermatitis and
skin cancer. Therefore it is important therefore to wear protective clothing when
handling.

Welding

Only competent persons who have undergone appropriate training should be


permitted to use welding equipment.

Protective Equipment appropriate to the type of welding must be worn.

Protective screens should be placed around electrical welding operations to prevent


others in the area from suffering from 'arc eye'.

Welding areas should be clear of flammable liquids and materials and great care
must be taken to ensure that any molten metal does not cause fire.

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Wheels And Tyres

Wheels and tyres are heavy items and great care exercised when handling, used
wheel handling equipment where possible or seek assistance.

Tyre pressures should be checked regularly and never be over inflated.

Wheel nuts should be checked to ensure they do not work loose tightening of wheel
nut should be carried out using a calibrated torque wrench set in accordance with the
vehicle manufacturer's recommendations.

Working Alone

Lone workers should not attempt to carry out any task that will put themselves or
others at risk or in danger and should never attempt to lift or handle heavy or bulky
items without the correct lifting.

Working Inside Tanks

If work is to be undertaken within the product tank, ensure the tank has been fully
drained and well vented before entering. Remove the manlids and allow the vehicle
to stand outside until all the fumes have dispersed. Never vent the tank with water
or steam, the water could contaminate the product. Meters are available which
can test the inside of the tank for toxic fumes; such a meter should be used to check
the tank before entering. Remember to have the meter checked and calibrated
regularly.

When working inside a product tank it is advisable to place a flashing warning lamp
on top of the tank to alert others that there is someone working inside. Have a
colleague periodically check that you are safe and well.

Workshop Environment

The Workshop should be kept clean and tidy and does not present a health and
safety hazard to themselves or others.

Good housekeeping practices should be applied to ensure rubbish, especially food


waste is held in covered bins that are emptied regularly to keep the premises clear of
pests.

Spillages should be cleaned up immediately.

Floors, steps, stairways and passageways should be kept clear.

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Aircraft Refuelling Operations

Aircraft refuelling operations should only be carried out by competent, well trained
operatives.

Before taking the vehicle out on a refuelling operation ensure that all the safety features,
deadman, interlocks, overrides etc are fully operational. Do not use a vehicle with faulty
safety equipment.

Be aware of what unit of measurement is displayed on the bulkmeter, litres, decalitres, US


gallons, Imperial gallons or weight. Failure to know this could result in too little or too much
fuel being delivered to the aircraft.

The hydrant dispenser should be positioned so that it can be driven away quickly in an
emergency.

Earthing And Bonding

Ensure that earthing and bonding procedures are carried out at all times.

Without adequate earthing a discharge of static electricity and consequently fire can occur.
Before fuelling operations commence, bond the vehicle to the aircraft with the bonding
cable before connecting the fuelling hose(s). On completion of fuelling disconnect the
fuelling hose(s) before removing the bonding cable.

Spillage’s

A major cause of spillage is other airport vehicle driving into


the intake coupling and breaking it off.

Stay well clear of the hydrant pit area mark it with a flag and
if possible fit a Fluid Transfer pit barrier to help prevent
damage to the coupling.

Connect a lanyard cable to the pit valve so it can be closed


quickly in the event of a spillage and be aware of the Pit Barrier
location of the nearest emergency stop button, located at
various points on the apron, that shut down the fuel supply in an emergency.

If an aircraft fuel valve malfunctions, fuel will overflow and spill from the aircraft wing vents.
Do not park or stand under an aircraft vent while the aircraft is being refuelled. Make sure
you know where these vents are located on the aircraft.

If any fuel spills onto your body or clothing, do not remove your clothing except under a
shower. If you take off your clothing without first dousing under water, you could create a
static spark and set yourself on fire.

Check the contents of the recovery tank, ensure that it does not become to full and
overflow. This also applies if the vehicle is fitted with an automatic emptying system, it
could be faulty.

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When operating in the stand off position ensure vehicles do not drive over the hoses.

In the event of a fuel spill, all equipment should be shut down and arrangements made to
have it cleaned up.

Fire

The flash point for jet fuel is a minimum of 38°C and avgas is volatile at any temperature.
If the ambient temperature is 38°C, jet fuel is already at flash point and only needs an
ignition source to start a fire.

Static electricity is one of the most hazardous sources of ignition. A refuelling vehicle must
be bonded to the aircraft to ensure that no sparks jump between the two bodies.

A safety zone of 15 metres radius should be established around the refuelling operation.
No lighters, matches, mobile phones, two-way radios, personal CD players or other
potential sources of ignition should be taken into this area.

In the event of fire do not use water to extinguish it, this will only spread the fire, use
AFFF foam or dry powder.

Safety Equipment

Always keep the deadman switch in your hand during a refuelling operation, never wrap a
band or tape around it to hold it closed nor wedge it into an opening on the vehicle. A Fluid
Transfer deadman timer system would elevate this problem.

Only use the deadman override in an emergency, when authorised to do so, to complete a
refuelling operation that has begun. Remove the vehicle from service, to have the fault
repaired, on returning to base.

Brake interlocks apply the vehicles handbrake, or prevent it being released, when an
interlocked item is incorrectly stowed. They are there to prevent the vehicle being driven if,
for example a hose has been left attached to an aircraft or the elevating fuelling deck was
still raised. Only use the brake interlock override in an emergency when the vehicle has to
driven clear of the area due to a major incident.

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