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Aviation Fuel Quality – We can’t afford to take chances
Prasad Ayyakad
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Aviation Safety
Aviation in itself is not inherently dangerous, but to an even greater degree than the sea, it is terribly unforgiving of any carelessness, incapacity, or neglect.
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Major risk events
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1. Aircraft Fire - Hydrant pit valve to refuelling vehicle system failure
2. Aircraft Fire - Refuelling vehicle fire, Loss of containment due to vehicle(s) / aircraft accidents
3. Aircraft Fire - Refuelling vehicle to aircraft hose/coupling system failure
4. Aircraft Fire - Aircraft fuel system failure (Wing Venting)
5. Aircraft Crash - Engine failure caused by water, dirt or debris
6. Aircraft Crash - Engine failure caused by lack of FSII
7. Aircraft Crash - Operator misfuels an avgas aircraft, Operator misfuels a jet aircraft or diesel aircraft
8. Aircraft Crash - Contaminated fuel, includes FAME
9. On airport driving incidents
10. Vehicle Accident - on road - spill/fire and personal injuries
11. Environmental - Leak from hydrant or cross-country pipeline
12. Depot fire – non tank related and Aircraft hits BP fixed or mobile facilities
13. Depot fire – fixed storage
14. Plane Crash - Wrong quantity of fuel delivered to plane (not plotted)
15. Crisis Management - Emergency Response
16. Security - Air BP facilities used for terrorist activities
17. Personal Injury - Health - Exposures (benzene/lead etc.) and International Travellers
18. Personal Injury - Slips, Trips and Falls (excluding non routine Working at Heights)
19. Personal injury - Musculoskeletal injuries
20. Personal Injuries - Non Routine Activities
21. HSE Legislation - non compliance
Increasing Risk
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Increasing frequency
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Aviation Supply Chain
• Every day 5 Million barrels of Jet transported
• 95,000 flights powered by Jet fuel
• 8 Million passengers transported daily
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Preventing delivery of grossly contaminated fuel to aircraft
Emergency landing of CX 780 in Hong Kong following delivery of grossly contaminated fuel in April 2010
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Standards
• To ensure good operability and long service life, the Aviation Industry seek to supply clean fuel to aircraft/engines.
• Cleanliness specifications are cited in API/EI 1550:
‘Handbook on equipment used for the maintenance and delivery of clean aviation fuel’.
− Maximum particulate content 0.00044 or 0.001 grams per litre.
− Typical into-plane particulate content is 0.00007 grams per litre.
Courtesy of the API/Energy Institute
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Fuel Quality Requirements - what the standards require
ASTM D 1655
• ‘7.1 The aviation turbine fuel specified in this specification shall be visually free of undissolved water, sediment, and suspended matter.’
Defence Standard 91-91
• ‘1.1 Appearance – Clear, bright and visually free from solid matter and undissolved water at ambient temperature.’
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Quality requirements
• expected time before overhaul of modern turbine engines
• long-haul aircraft carry more than 240,000 litres of product
• the aviation Industry has moved beyond simple visual quality control.
• Guidelines set stringent limits, typically less than 0.20 mg/litre dirt and less than 30 ppm of water at the point of delivery into plane.
• These are important as even small amounts of contaminant can quickly accumulate given the large volumes of fuel up-lifted for commercial flight
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Keeping the contaminants out
The Aviation Industry have developed equipment and procedures through-out the distribution chain to meet the challenge of clean, fit-for-purpose fuel on delivery.
• Three primary methods are used:
− Engineering
− Settling
− Filtration
In this session we will look at some interesting aspects of filtration from a practical perspective....
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Particulates in Aviation Fuel
• Particulate level and type can vary dependent on the point in the distribution chain where the sample is taken.
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On ReceiptOut of StorageInto Plane
Vic B. Hughes and Phil D. Rugen, IASH 2000, the 7th International Conference on Stabilityand Handling of Liquid Fuels, Graz, Austria, September 24-29, 2000
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Advances made by the industry
• Edition 6 monitors have now been implemented industry wide
• DP Limiting devices have been implemented in most locations
• Sampling processes have been tightened
• Training and assurance processes have been tightened
Do we need to do more …
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Case for doing more to keep particulates out
• However these are still inadequate in many systems as
− Number of legacy pipelines in the system
− Mostly not internally lined (epoxy coated) – except airport piping systems
− Filters change outs are expensive and time consuming
− Rust is a major cause of particulate contamination
− A serious incident like that of Surabaya can have disastrous results
So what did we do …..
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Magnastrain from BP
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Air BP Magnetic Strainer
• Intended for use as receipt filtration from third party pipeline systems with known problems of rust
• Extensive design and performance testing carried out
• Fully optimised and in service
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Unique features
• Unique modular design for ease of maintenance.
• Equipped with a fast open and close lid, and requires NO tools during maintenance, not even spanners!
• Operates without attention over its specified service interval
• Service times of less than 2 hours.
• Constructed from stainless steel and an operational life of >50 years.
• No significant running costs and no electrical requirements.
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Capabilities and advantages
• Operates at up to 500m3/hr, with the potential for increase due to its modular design.
• No detectable rust getting past the filter
• Have achieved a 100% increase of microfilter life
• Debris in conventional filter elements downstream of the Magnastrain reduced by >95%
• Service interval between 4 to 6 weeks.
• Valves downstream of the magnetic strainer can also benefit from increased life due to the removal of abrasive rust.
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• Vessel is manufactured from stainless steel
• All seals are Viton seals (chlorine resistant)
• Vessel build to UK and Industry codes and standards
• Rated to 18 bar
Magnastrain data
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Ease of operability
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The results speak for themselves …
Before Magnastrain
After Magnastrain
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• Air BP can design & install equipment
• Air BP can provide the commissioning services which include for vessel capture rates and metallic particle analysis.
• Provide procedures for operation & maintenance
• Train staff
• Provide on-going health & performance monitoring
At your service …
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Prasad AyyakadAir BP
We design, we innovate, we operate