燃油箱行业安全培训

Industry Fuel Tank Safety Training

上海科技宇航有限公司
STARCO
 背景知识
Background
• Why we study the course?

- In recent years the aviation industry has experienced a number

of incidents or accidents involving fuel tank explosions. These
events suggest that on some aircraft types, the fuel tank system
installation does not provide as high a level of protection
against explosion as had been expected.
- EASA Industry Fuel Tank Safety follow up meeting ---
Cologne 7 February 2006
- “FUEL TANK SAFETY: incorporation of the Critical Design
Control Configuration Limitations (CDCCL) into Acceptable
Means of Compliance for Part-M, Part-145 and Part-66”
- The definition of CDCCL does not include all the features
inherent in a design; it includes only information necessary to
ensure safety of fuel tank systems. The consideration
underlying this definition is that holders of type certificates
and supplemental type certificates should develop this
information and make it available to the operators of affected
airplanes.
- CDCCL should be identified in the airworthiness limitation
section of the Instructions for Continuing Airworthiness as an
Airworthiness Limitation Item (ALI). However, CDCCL are
not inspections or life-limited items, as are most existing ALIs.
CDCCL are features usually controlled by operators (or, where
necessary, holders of type certificates or supplemental type
certificates) through the development of appropriate
procedures.
- The US Federal Aviation Administration (FAA) has issued a
set of new rules related to fuel tank safety including SFAR 88
and appropriate amendments to parts of 14 CFR that require
fuel tank system design reviews, associated modification
reviews and improved maintenance procedures and practices.
- SFAR- Special Federal Aviation Regulation
- SFAR 88: “FUEL TANK SYSTEM FAULT TOLERANC
EVALUATION REQUIREMENTS”
(a) Conduct a safety review of the airplane fuel tank system to
determine that the design meets the requirements.
(b) Necessary design changes are identified within the
compliance time.
(c) Develop all maintenance and inspection instructions
necessary to maintain the design features required to preclude
the existence or development of an ignition source within the
fuel tank system of the airplane.
 Who should take the course?

• Personnel in aircraft and component shop maintenance

organizations involved in maintenance task planning, all
personnel carrying maintenance tasks on aircraft or
components classified as Fuel Tank Safety items, support staff
and certifying staff.
• Management, quality assurance personnel and auditors,
personnel in charge of stores, and any personnel not directly
involved in maintenance activities as required by the
organization
• AMC 145.A.30(e) Personnel requirements
Insert a new paragraph 11:
“Additional training in fuel tank safety as well as associated
inspection standards and maintenance procedures should be
required of maintenance organizations’ technical personnel,
especially technical personnel involved with the compliance of
CDCCL tasks.”
燃烧与燃油基本知识
Flammability and Fuel
Basic Knowledge
 燃烧的三要素
1. 热源 :热量
2. 燃料 :易燃物
3. 氧气 :空气

– 燃料剧烈氧化而发光、发热，称之为燃
烧。缺少或去掉三要素中的任何一个，
燃烧就会停止。
 如何防止油箱起火燃烧

• 控制起火源
Ignition source prevention
• 减少可燃性
Flammability reduction
• The most commonly recognized hazard
of fuel-tank work is the jet fuel itself. Jet
fuel is a flammable liquid and can be
ignited given certain ambient conditions,
primarily temperature and vapor
concentration.
 燃油蒸汽

• 燃油蒸汽比空气重3-4倍，会沉积在较低的
地方。一品脱燃油可以产生200立方英尺的
可爆炸混合物。燃油蒸汽于空气的混合大
约为1：100的燃油蒸汽，就已经足以构成
潜在的爆炸危险或火灾。
 航空煤油特性

• 航空煤油的闪点一般为40℃（100 °F ）左
右，如:JET-A为49 ℃。
• 航空煤油的燃点通常高于闪点50°F 左右。
 闪点和燃点
• 闪点又叫闪燃点，是指可燃性液体表面上的蒸汽
和空气的混合物与火接触而初次发生闪光时的温
度。各种油品的闪点可通过标准仪器测定。闪点
温度比着火点温度低些。
• 燃点又叫着火点，是指可燃性液体表面上的蒸汽
和空气的混合物与火接触而发生火焰能继续燃烧
不少于5s时的温度。可在测定闪点后继续在同一
标准仪器中测定。可燃性液体的闪点和燃点表明
其发生爆炸或火灾的可能性的大小，对运输、储
存和使用的安全有极大关系。
• The temperature at which the vapors of a flammable liquid can
ignite is known as the "flash point." A hazardous vapor
concentration is present when a fuel vapor reaches a level known
as the lower flammability limit (LFL) or lower explosive limit
(LEL). These limits are usually expressed as a percentage by
volume. Fuels below the LFL/LEL are considered too lean to burn.
If the fuel vapor concentration exceeds the upper flammability
limit or upper explosive limit, the fuel is considered too rich to
burn. A fuel vapor concentration between these two limits is
considered to be in its flammable range and will ignite and burn if
exposed to an ignition source. One of the best ways to control
unwanted fires and explosions is to keep the fuel vapor
concentration below the LFL/LEL, preventing it from reaching its
flammable range. Other flammable chemicals may also be present
during fuel-tank work. Chemicals with a low flash point (less than
70ºF (21ºC)), such as methyl ethyl ketone (MEK), are even more
hazardous than jet fuel, and their use must be strictly controlled.
• ENSURE ADEQUATE VENTILATION

The single most important method of controlling the

fire, explosion, and toxic hazards associated with
working in an open fuel tank is ventilation. The more
fresh air that is present in the fuel tank, the safer the
environment will be for maintenance personnel.
Continuously pushing fresh air into a fuel tank helps
to prevent a fuel vapor concentration from reaching
its LFL, thus preventing fires and explosions. Fresh
air also dilutes the vapor concentration of toxic
chemicals, reducing the risk of hazardous exposures.
• ELECTRICALLY POWERED EQUIPMENT

Maintenance technicians may need to use a variety of

energized equipment, including lighting, testing
equipment, and powered tools. All electrically
powered equipment must be intrinsically safe or rated
for use in a potentially flammable atmosphere.
Pneumatic tools should be powered only by
compressed air, not by nitrogen or other inert gas that
could displace the oxygen inside the tank.
 加抽油时的防火安全

 给飞机加油时，蒸汽从燃油箱中升
起，火星可以点燃这些燃油蒸汽。
 燃油流入软管时产生静电。
 静电特点

• 静电电位往往高达几千伏，甚至几万伏。
• 静电感应和感应起电，可能在导体（包括
人体）上产生很高的电压，有时是导致危
险的火花。
 加抽油工作安全注意事项
Refuel/Defuel Safety Precaution
 加抽油预防措施
• 加抽油时，飞机上或周围不允许抽烟。应禁止
诸如油灯、蜡烛或火柴等的火苗，在距离加油
或抽油的飞机100英尺的范围内，决不允许有外
露电门、汇电环或整流器、发电机或电动机以
及产生火花的电气设备，或任何易燃物质。
• 加抽油过程中，对洒到外面的燃油要及时处理：
- 大量洒出：洒乳化剂，使不易燃，后用水冲洗干
净
- 少量洒出：洒沙子，清扫。
• 不允许在加油和抽油期间用无线电设备和
雷达（包括手机），不需要的外部电源应
断开，与加油有关的电路可以接通。
• 飞机加油和抽油时应注意三接地：
- 油车接地，飞机接地，加油管接地
- 飞机与管路扣连，放静电
• 抽油时仔细检查放出的燃油有无杂质，鉴
别是否能放入燃油箱，飞机附近应放灭火
瓶
• 在易燃液体周围工作的人员不应穿人造丝、
尼龙、丝绸、毛料和化纤服装，因为这些
材料容易产生静电火花
燃油箱工作安全注意事项
Fuel Tank Safety Precaution
 燃油箱工作注意事项
Fuel Tank Safety Precaution

• 人员
Approved Persons:
Persons who are trained and understand the dangers
and procedures for fuel tank entry and are responsible
to make sure the airplane, equipment and the
environment is safe for maintenance operations.
• 防火安全条件
FIRE-SAFE CONDITION:
- A FIRE-SAFE CONDITION OCCURS WHEN THE VAPOR
CONCENTRATION IS LESS THAN 10 PERCENT OF THE
LOWER EXPLOSIVE LIMIT (LEL)IAW BOEING AMM.
- A FIRE-SAFE CONDITION OCCURS WHEN THE VAPOR
CONCENTRATION IS LESS THAN 5 PERCENT OF THE
LOWER EXPLOSIVE LIMIT (LEL)IAW AIRBUS AMM.
• 健康安全条件
Health-Safe Condition:
- An atmosphere where oxygen content is a minimum of 19.5% to
a maximum of 23.5% by volume at sea level, and the vapor
concentrations are below the permissible exposure limits (PEL).
- Because kerosene has a low vapor pressure, the concentrations
are usually within the limits needed for a Health-Safe
condition. Thus, you usually get very low (safe) values at
usual temperature (less than approximately 70 °F). At tank
temperatures of approximately 90 °F, it is possible to get gas
concentrations more than the Health-Safe value with kerosene.
At tank temperatures of more than 90 °F, it is possible to get
gas concentrations more than the Fire-Safe value. It is also
possible that a different type of fuel was kept in a tank that
usually contains kerosene. If the purging procedure was not
done, this causes high concentration values when you use the
combustible gas indicator.
 清洁油箱注意事项
Purging or Purged For Fuel Tank Entry

• Purging an aircraft fuel tank is defined as the removal

of any fuel or fuel vapor that remains after the fuel
tanks are sumped. A purged fuel tank contains a
nonflammable atmosphere that can be maintained by
mechanical ventilation.
• 禁止的起火源
Unwanted Sources of Ignition:
1) open flames (matches, cigarette lighters etc.)
2) electrical equipment (lights, motors, sparks from
engine exhaust etc.)
3) frictional hot spots
4) electromagnetic energy (radio transmissions or radars)
5) static electricity
6) lightning
 飞机注意事项
Airplane Precautions

• The airplane must be correctly grounded to an approved

ground before you defuel the airplane or open any fuel tanks.

• WARNING: DO NOT USE AIRPLANE ELECTRICAL

POWER WHEN FUEL TANK ACCESS DOORS ARE OPEN.
A FIRE OR EXPLOSION CAN OCCUR IF FUEL VAPOR IS
IGNITED BY SPARK(S) FROM ELECTRICAL
EQUIPMENT. A FIRE OR EXPLOSION CAN CAUSE
SERIOUS INJURY OR DEATH TO PERSONS AND CAN
CAUSE DAMAGE TO EQUIPMENT.
• Before the fuel tank access doors are opened, all of the
electrical power to and from the airplane must be removed.
• The main storage battery must be disconnected.
• All safety, support and maintenance equipment must be in
place before you open the fuel tank access doors. Movement
of equipment can cause sparks which can cause fuel vapors to
ignite.
• No painting operations are permitted on airplanes with open
fuel tanks.
 电气设备注意事项
Electrical Equipment Precautions

• No radio or radar equipment should operate nearer to

an open fuel tank than the distances specified in Table
201.
*[3] This category includes mobile phones, pagers, two-way
radios,etc.
• Fuel in the beam of operational high-powered radar
which can produce a peak power density that exceeds
5 watts per square centimeter is hazardous.
Electromagnetic energy of this intensity can ignite
fuel vapors and cause a fire.
• Only use approved explosion-proof flashlight that
operate correctly in the fuel tanks.
• NOTE: The use of explosion-proof lights in or near
an open fuel tank is allowed only by approved
persons. The air in the fuel tank must be 10 percent or
less of the lower explosive limit (LEL).
• Only use explosion-proof flood extension lights and
power cords which are approved to supply external
light.
• Do not connect or disconnect electrical equipment
from energized outlets (within 100 feet [30 meters] of
an open fuel tank) unless the equipment is fitted with
explosion-proof plugs.
• Do not use electrical test equipment which can cause
sparks in a fuel tank.
 地面设备注意事项
Equipment Precautions

• All metal work platforms or stands used for entry into the fuel
tanks or found within a 50-foot (15-meter) radius of an open
fuel tank (before and after the fuel tank purging) must be
bonded to the airplane and grounded to an approved earth
ground.
• Before you use ventilation equipment make sure the blower or
venturi is connected to the airplane ground. The ventilation
blower or the venturi must be explosion-proof.
• Air ducts must be bonded to form a continuous electrical
conductor, and grounded in at least one location to a static
electrical ground.
• Equipment used to ventilate the fuel tanks or provide warm or
cool air must not be turned off with the air duct in the fuel tank.
The fuel vapor from the fuel tank can enter the air duct and
cause an explosion at the motor. Make sure the blower is on
before you put the air duct in the fuel tank. Make sure the
blower remains on until the air duct is removed from the fuel
tank.
• 油箱内使用工装注意
Obey these precautions for equipment used to do maintenance
in the fuel tanks:
(a) Only use approved non-static plastic containers with rounded
corners to hold tools and supplies.
(b) Keep all sharp edged tools in the container at all times when
not in use. Sharp edged tools can cause damage to equipment
and sealant.
(c) Only use cotton wipers to wipe up fuel in open fuel tanks.
(d) Solvents, sealants, or other materials used in the fuel tank can
be a health and fire hazard. Use the correct protective
equipment for the solvent or material that is used. Protective
equipment includes: respirators, eye protection, protective
clothes, gloves etc.
(e) Keep the quantity of solvents that you use to a minimum.
Only bring enough solvent in the tank to complete the
maintenance.Apply the solvent to a clean cotton wiper, not the
airplane structure or sealant. After you finish with the cotton
wiper, put the cotton wiper in apolyethlene bag or remove the
cotton wiper from the airplane. This will keep the solvent
vapor to a minimum.
(f) Powered tools must be air driven.
(g) Only use shop air or bottled air as a gas source for air-driven
tools. Do not use nitrogen, oxygen, carbon dioxide (CO2) or
any other non-air source of gas.
 人员注意事项
Personnel Precautions

• Persons who work in or near an open fuel tank must not:

(a) Slide metal objects, such as tool boxes, ladders, etc.
(b) Carry matches or pocket warmers.
(c) Wear shoes with metal clips or exposed nails.
(d) Wear or use battery-operated devices such as hearing
aids,electrical pacemakers or watches, pocket radios, cellular
phones or paging equipment unless it is explosion-proof and
permitted by approved persons.
• Persons who work in an open fuel tank must wear approved
fuel tank protective clothing. Protective clothing includes:
Cotton coveralls with non-sparking zippers or buttons. Do not
wear wool, silk, nylon or other synthetic clothing.
• Persons who work in or near an open fuel tank must not
remove or change clothes near an open fuel tank. You can
create sufficient static electricity in the clothes to cause fuel
vapor to ignite.
 恶劣天气状况注意事项
Adverse Weather Conditions

• When thunderstorms or lightning are within a 10 mile (16

kilometer) radius of the immediate area, open fuel tank
maintenance procedures should stop. Persons inside of the fuel
tanks should get out. Air ducts inside the fuel tanks should be
removed and the power for all support equipment should be
switched off. The fuel tank access openings must be closed.
• Strong wind conditions can cause a build-up of static
electricity.Large charges of static electricity can develop on
support equipment while parked as a result of the movement of
dust particles and air currents during strong wind conditions.
Strong wind conditions can also cause the unwanted
movement of items or equipment which can hit the airplane or
injure persons. Wind gusts can damage the airplane structure.
Fueling, defueling or open fuel tank maintenance procedures
should stop if strong wind conditions are present.
 航空器燃烧事故
Aircraft Accident Case
2007年4月19日海湾航空维修公司（GAMCO）空客飞机燃烧
2007年8月台湾华航客机在日本那霸机场起火爆炸
• That accident resulted from reports of parts of the main slat
track downstop assembly coming off the main slat track. In
one case, a bolt fell into the slat track housing (referred to as
“slat can”) and, during a subsequent slat retraction, the track
made contact with the bolt, pushing it into the wall of the can
and puncturing it. That operator reported finding fuel leaking
from the drain hole in the slat track housing at the slat track
position, which resulted in a fuel leak and a fire that ultimately
destroyed the airplane.
1996年7月波音747在纽约爆炸
• PROBABLE CAUSE:
"An explosion of the center wing fuel tank (CWT), resulting
from ignition of the flammable fuel/air mixture in the tank.
The source of ignition energy for the explosion could not be
determined with certainty, but, of the sources evaluated by the
investigation, the most likely was a short circuit outside of the
CWT that allowed excessive voltage to enter it through
electrical wiring associated with the fuel quantity indication
system.
• Fuel tank inspections
- Inspected for adequate bonding of fuel system components
and damaged wiring.
• Modifications
- To comply with SFAR No. 88, it must be shown that the energy
level on all wiring inside the fuel tanks is incapable of
causing ignition in an explosive atmosphere, even under
certain fault conditions.
- Current Limiting devices: The surface temperature of some
components mounted inside the fuel tanks may become above
critical levels if the parts are exposed to excessive voltages due
to wiring shorts with other electrical systems.
- Flame arresters: Currently under investigation is the
requirement for the installation of flame arresters in the fuel
suction lines.
• Safety review
• Documentation
- review the existing "Zonal Inspections" and check their
contents to verify that the newly issued inspection
requirements are cover in the existing inspection.
- update the existing aircraft documentation with specific
bonding procedures.
• Compliance Program
- a complete package to make the fleet compliant to SFAR-88.
 谢谢
THANK YOU !