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Book 11 Module 7A
CATEGORY B1 B2 AIRCRAFT HANDLING
CONTAMINATION & CLEANING COLD WEATHER PRECAUTIONS
Licence By Post
For best examination results always use latest
issue number.
Licence By Post © Copyright B EASA 66 7A.17 ISSUE 09 1012
© Licence By Post
No part of this study book may be re-produced or distributed in any form or by any means, or stored in a data base or retrieval system in whole or in part without prior written permission from Licence By Post. Books in the LBP series are regularly up-dated/re-written to keep pace with the changing technology, changing examination requirements and changing legal requirements.
AUTHORITY
It is IMPORTANT to note that the information in this book is for study/training
purposes only.
When carrying out a procedure/work on aircraft/aircraft equipment you MUST
always refer to the relevant aircraft maintenance manual or equipment
manufacturer’s handbook.
You should also follow the requirements of your national regulatory authority (the
CAA in the UK) and laid down company policy as regards local procedures, recording,
report writing, documentation etc.
For health and safety in the workplace you should follow the regulations/guidelines
as specified by the equipment manufacturer, your company, national safety
authorities and national governments.
ACKNOWLEDGEMENTS
With special thanks to:
AIRBUS INDUSTRIE
BRITISH AEROSPACE
UK CIVIL AVIATION AUTHORITY
for permission to reproduce drawings.
ADDENDUM Addendum action in response to student feed-back after taking the CAA
examinations.
***
Question on Hogging. This subject is not listed in the module 7 syllabus but is listed
in the module 11 syllabuses. It is the tendency of the fuselage to be bent after a
heavy landing. The front and rear of the fuselage are bent down low and the middle is
high. When it bends the other way (low in the middle and high at the ends) it is called
sagging. Tolerances will be allowed (AMM/SRM) in both cases and if within tolerance
the aircraft is returned to service after a thorough inspection for other damage. Where
no tolerances are given or where they have been exceeded then the manufacturer will
have to be consulted and the aircraft withdrawn from service until the problem has
been rectified.
***
Question on external flying control locks fitted to control systems fitted with spring
tabs. If the control lock fits to the control surface and does not cover the tab then the
control column can be moved as it is connected directly to the tab (and the tab will
move). In very general terms the control column is connected directly to the tab and
the tab is connected to the control surface via a spring.
*****
CONTENTS
Page
Ramp maintenance 1
Aircraft movement 5
Marshalling 5
Towing 10
Parking 13
Mooring/picketing 14
Jacking/trestling/shoring 18
Cold weather precautions 25
Ice and snow formation on aircraft 26
Ground de-icing 27
Ice and snow removal 28
Refuelling/defuelling 34
Aircraft cleaning 41
Ground service connections 49
Appendix – CAA essay questions 55
HOW TO TACKLE THIS BOOK
Written to level 2 of the EASA Part 66 syllabus module 7A for the mechanical (B1)
and avionic (B2) aircraft maintenance engineer.
For the category A line maintenance engineer you are referred to the LBP book set
module 7 specifically written to the A standard. The B3 engineer should study the B3
book set.
This book deals with subjects having separate ATA chapters in the AMM:
Chapter 7 - Lifting and shoring.
Chapter 9 - Towing.
Chapter 10 - Parking, mooring and storage.
Chapter 51 - Cleaning.
Have a look at these areas for your aircraft and note any differences/ similarities to
the contents of this book.
Note. Drawings taken from CAPs (Civil Air Publications) may not be found in those
publications due to amendment action.
The author has used large aircraft as examples on the understanding that if the
student knows how to handle the bigger ones then the smaller aircraft will be the
same but without some of the procedures – also the CAA would expect that all B1/B2
engineers know the details to this level anyway.
The subject of Cleaning has been included, this is because the CAA have been known
to ask questions (essay) on this subject for module 7. Cleaning is listed as a subject
in modules 11 though it is not listed as such in module 7. It could, however, be
included as part of the listings, Aircraft Handling & Storage or Abnormal Events.
Note that with all procedures the AMM (Aircraft Maintenance Manual) must always
be consulted.
RAMP MAINTENANCE
The CAA will expect you to be able to ‘see’ an aircraft in after a flight and ‘see’ it out.
It may be a small aircraft with no passengers, it may be large with several hundred
passengers on board. You must be aware of all the maintenance that has to be
carried out. The fundamental checks to be carried out on all aircraft are similar in
terms of refuelling, rectification of any defects, before flight inspections, after flight
inspections, etc.
There are, of course, variations and that is where the aircraft maintenance manual
(AMM) comes in – always refer to it to check for the correct procedures to be carried
out.
The following paragraphs indicate some general points to be considered for a
passenger aircraft. If you can understand how to cope with a large aircraft then the
smaller ones should be easy.
Aircraft Arrival (Figure 2)
1. Check AMM for procedure to be followed (after-flight inspection,
refuelling etc.)
2. Ensure the area is clear of all equipment and debris/snow etc.
3. Ensure that the required maintenance equipment is standing by,
eg, equipment for: baggage handling; refuelling; toilet servicing;
system maintenance – electrical – hydraulic etc.
4. Ensure servicing personnel available.
5. Ensure any spares are available – may have been radioed forward via a
datalink from the aircraft (automatic on some aircraft).
6. When aircraft arrives marshal it in, chock wheels, shut down engines,
put brakes off. Fit landing gear ground locks, flying control locks, and
fit airframe/engine/systems covers if aircraft is to remain on the ground
for a time.
7. Load/unload aircraft (cargo, baggage, passengers).
8. Carry out after-flight inspection. If aircraft taking off soon carry out
between-flight inspection, and replenish consumables. Clean cabin,
galleys and toilets. Rectify any defects.
9. Secure aircraft if it is not leaving straight away.
10. Complete details in the Tech Log and sign.
11. Secure aircraft.
Aircraft Departure (Figure 2)
1. Carry out before-flight inspection (AMM) or between-flight inspection as
necessary. Ensure correct fuel load. Ensure toilets and galleys are
serviced and provisioned and cabin areas cleaned.
2. Make up Weight and Balance Schedule.
3. Check loading (passengers/cargo) and fuel state – make up load sheet
(see later chapters in this book).
4. Remove all covers and ground locks.
5. Ensure aircraft is free of ice and snow. Check weather conditions and
hold-over times.
- 1 -
6. Clear Tech Log and sign. Check deferred defects against the MEL
(minimum equipment list). Ensure pilot is informed of any deferred
defects carried. Pilot to sign Loading Data Sheet.
7. Check all doors, hatches etc are closed and passenger ramps pulled
back out of the way.
8. Connect mic/tel lead to aircraft.
9. Ensure ground crew in place and check with pilot.
10. Ensure equipment available for ‘push back’ (see figure 1).
11. Isolate nose wheel steering.
12. Connect correct towing arm to aircraft and tug.
13. Clear area – start engines, if allowed before push-back (at some airports
engines must be started only after pushback) – remove chocks.
14. After checking with pilot (he/she will get clearance from ATC) push
aircraft back using the tug. Ensure adequate clearance between aircraft
wingtips and tail – use look-outs if necessary.
15. After push-back reinstate nose wheel steering, disconnect towing arm,
hand over aircraft movement control to pilot and remove mic/tel lead.
Fig. 1 TOWING THE A310
The Ramp
The Ramp or Line is the area where cargo, passengers and crew are transferred to
and from the aircraft. It is also the area where a great deal of maintenance is carried
out. Some people call this first-line servicing, others call it ramp maintenance.
Besides rectification of minor defects that have occurred during the previous flight
and before-flight/after flight/turn round inspections are carried out the aircraft has
to have consumables replenished and be cleaned.
With most airlines the following tasks are performed using contractors:
* Refuelling.
* Toilet waste disposal and toilet tank replenishment.
* Drinking water (potable water) tank/s replenishment.
* Oxygen/compressed air systems replenished.
* Cabin, galley, toilet cleaning.
* Galley stock replenishment.
* Aircraft snow removal/de-icing carried out.
- 2 -
Figure 2 shows the various external connections for the ramp maintenance of the
B747 as well as the location of the various maintenance vehicles during turn round
operations.
The B747 is taken as an example as it has most of the systems/equipment used in a
turn-around. Take a moment to study the drawing and note the various maintenance
vehicles and maintenance vehicle connections.
Although contractors may perform most of this work the aircraft is still ‘yours’ and all
work will come under your signature for clearance for flight. So you will need to know
what is going on.
Fig. 2 RAMP SERVICING THE B747 – AN OVERVIEW
- 3 -
Fig. 3 AIRCRAFT MOVEMENT – GENERAL
With reference to figure 3. If the aircraft is to be moved using the engines then it
must be in accordance with company policy and the person running the engines
must be cleared to taxi the aircraft under power. With the other two methods of
aircraft movement a qualified person must be on the brakes.
Because of the complexities of ramp maintenance there has to be co-ordination
between various people/teams/contractors, to include:
* Engineer in charge of the technical side of the aircraft (you).
* Refuelling team.
* Galley replenishment team.
* Toilet effluent removal team.
* Aircraft cleaners (internal).
* Aircraft cleaners (external). Not often used.
* Baggage handlers/cargo loaders.
* Passenger administration (security, baggage, check-in, movement etc).
* De-icing team.
On small aircraft all of the appropriate items above would be completed by you so
you would know what is going on. On large aircraft this would not be possible so
often a Ramp Manager/Ramp Co-ordinator is used. His/her job is to co-ordinate all
of the above activities and ensure that all are completed in the correct order. You
would check with him/her on the readiness state of the aircraft.
- 4 -
It would be up to the operator to set up this organisation and to define the
responsibilities of the individual groups/sub-contractors. This would be part of the
company’s exposition – including all safety aspects.
AIRCRAFT MOVEMENT
An aircraft may be moved:
* Under it’s own power using flight crew or ground crew (in some
organisations ground crew can be certified to taxi aircraft).
* Manually – pushing by hand. Quite easy for small aircraft but much
more difficult for the larger ones – though it can be done if needs must
and you have enough manpower. Remember there are some parts of an
aircraft that are not strong enough to be pushed on. These are indicated
in the AMM and have warnings painted on the area such as NO PUSH,
DO NOT PUSH HERE etc.
* Using a tug/tractor and towing gear.
* Using a special hand operated towing trolley that is self-powered and
connected to the nose/tail wheel direct.
MARSHALLING
When the aircraft is moving under its own power and it is in the ramp area it should
be marshalled by qualified personnel. It is difficult for the pilot to judge wing-tip and
tailplane clearances and it is also impossible for him/her to be fully aware of other
aircraft and vehicular traffic in the area.
The person-in-charge is the marshaller who should stand where the pilot can see
him/her – usually in front and to the left (port side) of the aircraft. The marshaller
should be able to see (and be seen) by all other ground crew involved in the
movement of the aircraft. The number of crew depends on the size of the aircraft but
in general there is:
* 1 marshaller.
* 2 wingwalkers – to check wing-tip/helicopter blade clearances from
nearby aircraft/equipment/buildings.
* 1 person at the tail.
All personnel should be aware of the dangers of aircraft moving under their own
power. These include:
* Noise.
* Blast from jet engines.
* Dust and airborne debris from jet engines, propellers, rotorblades.
* Dangers from jet engine intakes.
* Propeller blades.
* Helicopter rotor blades (main and tail).
If the engines are likely to be noisy then ear defenders are to be warn and if the
marshaller is required to walk backwards then he/she should ensure that the ground
behind him/her is free from equipment, safe to walk on and be aware if any
aircraft/vehicles move into the area.
- 5 -
CAP 637 Visual Aids Handbook published by the CAA show the recommended
signals to use and the ICAO recommended signals are similar. Also CAP 462
Helicopter External Load Operations show hand signals for helicopters. There are
variations depending on where in the world the marshalling is carried out and there
are also some signals, such as ‘thumbs-up’ (affirmative – positive) and ‘thumbs-down’
(cannot confirm –negative) used widely.
Illuminated wands should be used – particularly at night.
Reference figures 4, 5 and 6 Marshalling Hand Signals.
Note 1. Where the word ‘pilot’ is used the word ‘aircrew’ or ‘flightcrew’
can be substituted.
Note 2. When hand signals are given to the pilot it is important that the
marshaller ensures that he/she has made eye contact with the pilot.
Note 3. Hand signals (i) and (j). Raised fingers can be used to indicate the
engine referred to. The engines are numbered from the port (left) side
to the starboard (right) side of the aircraft:
1 finger 2 fingers 3 fingers 4 fingers
ENGINE 1 ENGINE 2 ENGINE 3 ENGINE 4
The ‘raised finger’ signal can be used by the pilot to indicate an
engine.
Note 4. Hand signals (m) and (n). These signals (and others) can be used by
the pilot to indicate the same meaning.
Note 5. Hand signal (q). The thumbs-down sign is used as a
negative/none affirmation signal. Used by ground and air crew.
Note 6. Hand signal ( r). The drawing shows the command to the pilot to
move
the tail to the right (starboard) whilst the aircraft is backing. The
hand signal with the right hand is a ‘move-back’ signal. For the
aircraft to move tail left the same signal is given but with the other
hand.
Some aircraft can taxi backwards (if allowed in the AMM). Some
piston engined aircraft with reverse pitch propellers for example. In
these circumstances it is important that the marshaller wear eye
protection as there may be a lot of dust and debris in the air.
Note 7. Hand signal (w). For unplugging ground power the signal is the same
except the movement of the right hand is reversed. It is pulled down
from the left hand in an ‘un-plugging’ movement..
Note 8. Many of the signals shown in figures 4, 5 and 6 can be used for both
fixed wing and rotary wing aircraft, however those showing the
helicopter symbol are specific to helicopters.
Note 9. Hand signal (aa) shows move-right. Move-left is similar but with the
hand positions reversed .
Note 10. Hand signal (ab) shows the command to move-up. To indicate move-
down the palms of the hands are turned down and a flapping-down
motion is given.
Note 11. Hand signal (ac). This move-back signal is given in CAP 637. In CAP
462 the move-back signal is shown as both arms down by the side of
the body sweeping forward to the horizontal position repeatedly. If
you get a question on this in a CAA exam you should bring this to the
attention of the invigilator.
- 6 -
Fig. 4 MARSHALLING HAND SIGNALS - 1
- 7 -
Fig. 5 MARSHALLING HAND SIGNALS – 2
- 8 -
Fig. 6 MARSHALLING HAND SIGNALS - 3
- 9 -
TOWING
In general when towing, it should be on firm level ground, and a towing arm may be
used attached to the nose wheel or tail wheel. When towing on soft ground a bridle is
used attached to the main landing gear with a steering arm attached to the tail wheel
or nose wheel.
Fig. 7 TOWING THE B747
Towing Bridle and Steering Arm
On soft or uneven ground, tail wheeled aircraft are towed forward by a towing bridle
or frame attached to the main landing gear. The steel cable of the bridle is threaded
through a towing attachment on the tug containing a pulley in which the cable rides.
The free ends of the cable are attached to towing lugs on the main landing gear. A
steering arm is attached to the tail wheel.
Fig. 8 TOWING BRIDLE
With aircraft fitted with nose wheels, the towing bridle may be used for forward or
backward movement (provided it says so in the AMM), and is fitted to the front or
back of the main landing gear.
- 10 -
To tow the aircraft forward a towing bridle is used fitted with a special towing arm
attached to the nose wheel. The tug end of the towing arm contains a pulley through
which the towing bridle cable passes. This allows the aircraft to be steered by the
towing arm while even tension on the towing bridle cable is maintained to the main
landing gear.
Towing Arm
When towing an aircraft in the hangar or on hard level standing a towing arm only
may be used. It is fitted to the nose or tail wheel and usually incorporates a spring
shock absorber, and is fitted with a shear-pin to prevent excessive loads being placed
through the nose or tail unit. If a sudden load is placed through the towing arm by
the tug the shock absorber should cope with it and if it can’t, the shear-pin will shear
thus preventing the load being put through the landing gear which will damage it. On
some towing arms the shear pin may have positions for more than one aircraft type –
for example: B727, B737, etc. Ensure that the pin is in the correct position.
Towing Frame
A towing frame may be used on light aircraft. It provides positive control of the
aircraft by the tug and a steering arm is not required. May look antiquated but does
provide complete control of the aircraft during acceleration, turning and braking by
the tug/tractor driver.
Fig. 9 TOWING FRAME
QUESTION What are the checks and precautions required when towing an aircraft?
(10 mins).
ANSWER 1. Check the AMM. Check C of G is within limits and any
windspeeds (check ATC) are within limits consistent with tyre
coefficients of friction (wet conditions, ice on ground etc). Check
maximum angles of towing arm to fuselage centre-line (in the
AMM and painted on the nose gear).
2. Always ensure the aircraft is serviceable to tow eg:
(a) Landing gear ground locks fitted.
(b) ‘Three Greens’ on the flight deck landing gear indicator .
(c) The brake system is serviceable and pressurised.
- 11 -
(d) The aircraft is structurally intact. All stress panels fitted.
Check if windscreen has to be fitted prior to movement
(applies to some small aircraft).
(e) The tyres and shock absorbers are correctly inflated.
3. Ensure that the correct number of personnel are used and
the person on the aircraft brakes is competent to use them (many
operators insist on the person having passed a test first before
he/she is issued with a ‘brakes ticket’).
4. Ensure power steering is off or disconnected.
5. The tug driver should be qualified and take his/her orders
from the person in charge.
6. The person in charge should be able to communicate with
all the others involved in the towing operation.
7. Look-outs should be positioned at the extremities of the
aircraft – wing tips and tailplane.
8. Turn corners with as large a radius as possible and do not
exceed the minimum turning radius as stated in the AMM.
9. Maximum towing speed is walking speed – unless local
regulations permit otherwise.
10. Ensure navigation (anti-collision) lights are on. Power will need to
be on.
11. Get permission from Air Traffic Control (ATC) before towing in the
ATC zone.
12. Tow only on firm level ground.
13. When finishing the tow ensure that the wheels have revolved at
least one revolution (some manuals give an actual distance) in a
straight line to relieve tyre and landing gear side and torsional
stresses.
14. Disconnect towing gear, re-instate nose wheel steering and chock
wheels. Secure aircraft if it is to be left and switch lights and
power off.
Towing should always be carried out using the correct equipment supplied for the
job. If it is absolutely necessary to tow an aircraft and the correct equipment is not
available then ropes may be used attached to the main landing gear. The best ropes
to use are polymer ropes such as Nylon, Dacron or Polypropylene. The aircraft
operator will have a policy for this and the chief engineer would normally be called.
Figure 10 shows the AMM details of the minimum turning radii for various parts of
the B747. Note the Pavement Width, the towing conditions and the steerable body
main landing gear. There is no need to commit the details to memory.
All aircraft manuals will have drawings similar to this showing details of the towing
equipment, speeds, wind conditions, minimum turning radii, straight line finishing
runs etc.
Remember, when towing an aircraft (helicopter or fixed wing) the minimum bend
radius must not be exceeded. If the aircraft is turned around too small a radii the
main landing gear on the inside of the bend is likely to suffer damage particularly if it
is of the bogie (multi-wheeled) type with a large ‘footprint’.
- 12 -
This is because when going round a bend the aircraft tends to move about the inside
main landing gear; the landing gear will resist this movement and high torsional
stresses will be set up. These forces can be high enough to cause the inside of the
shock absorber to rotate in the outer case and cause the torque links to shear.
Helicopters may have 2 main wheels and a nose or tail wheel or 4 main wheels.
Helicopters with skids have transport wheels fitted for towing purposes.
Fig. 10 TURNING RADII - B747
PARKING
When parking an aircraft the following precautions must be observed:
1. Refer to the AMM.
2. The aircraft should be parked in such a way so as not to obstruct the
movement of other aircraft or equipment.
3. Park nose into wind where possible on firm level ground.
- 13 -
4. Intake and Pitot-static blanks should be fitted, also undercarriage and
control locks and covers where specified in the AMM.
5. Chock wheels fore and aft and put brakes off.
6. Secure aircraft doors and hatches.
MOORING/PICKETING (Figures 11 to 16)
This is not too unlike parking an aircraft except that it is carried out when the
aircraft is likely to be left in the open for a long period of time. Whether the aircraft is
to be parked or moored will be a decision made locally but will be dependent on how
long it is to be left and what the expected weather conditions are likely to be.
It is advisable to moor an aircraft if it is to stand outside for long periods. This
applies particularly to small aircraft which would otherwise be damaged in high
winds. In very general terms the aircraft is tethered to the ground, all covers and
locks are fitted and the aircraft made safe. Tethering points on the aircraft are
classed as:
* Main picketing/mooring/tiedown points – usually the landing gear.
* Secondary picketing/mooring points – might include wing tips, tail
plane, helicopter blades.
After consulting the AMM the following points should be observed:
1. Move aircraft to an area where ground/mooring points are provided (if
available). These may be steel rings set in concrete flush with the
ground and spaced at regular intervals in a circle. The aircraft landing
gear is lashed to these. Some airfields have long lengths of thick cable
fixed to the ground in areas where mooring is permissible. The aircraft
is moved so the main gear can be tied with rope to the cable. If mooring
rings/cables are not provided then heavy items of equipment can be
used or screw pickets can be screwed into the ground (if mooring off the
hard standing).
2. Proceed as for parking.
3. Fit ‘weather’ covers to wheels, cockpits, engine intakes, exhausts, Pitot
static probes, TAT probes etc.
4. Isolate fuel tanks and battery (in some aircraft the main battery is left
connected to provide power to the fire detection and extinguishing
systems). In some cases the fuel tanks are filled so as to prevent the
linings drying out and cracking.
5. Secure the aircraft to the ground using the main and secondary
mooring points. Use ropes or chains.
6. Drain drinking water (potable water), remove perishable goods and
valuable and attractive items, first aid kits etc.
7. Move aircraft regularly to avoid tyre flat-spots and bearing brinnelling.
8. Carry out regular checks of the aircraft in accordance with the manual
(weekly and/or monthly).
9. For helicopters remove or secure blades (folded and secured to the
fuselage or tethered to the ground).
10. For turbo-propeller driven aircraft secure propeller/s to prevent them
‘wind-milling’ in the wind.
11. Record all work done in the log book and sign.
- 14 -
Figure 11 shows the mooring of a Boeing 747 and figures 12 to 16 show details of
mooring a Shorts 360 turbo-prop aircraft. The B747 is typical of a large commercial
aircraft and the 360 is typical of a small to medium size aircraft. You need not
remember the details in each case but, you would be required to be able to explain
how you would go about mooring an aircraft.
Note the use of the following:
* Warning flags on covers and blanks.
* Blanks or bungs for all major aircraft orifices.
* Mooring harnesses for the propellers.
* Mooring rings in the ground.
Fig. 11 MOORING THE B747
The tie-down may be performed using cables with end fittings to fit the aircraft tie-
down points. When ropes are used the best ones to use are Nylon, Dacron or
Polypropylene (stronger and less prone to rot than natural fibre ropes).
- 15 -
If manila is used it will shrink when wet and slack has to be allowed for this (about
1” for small aircraft, larger amounts for big aircraft). Anti-slip knots should be used
such as the bowline. Make sure that ropes/cables used are strong enough (have the
minimum breaking load as laid down in the AMM).
If the ropes are tight to the secondary mooring points damage may occur to these in
high winds. When the aircraft moves in the wind the stain on the secondary points
may be too much and damage might ensue. Secondary mooring points include wing
tips, tailplane on a nose wheel aircraft, possibly podded engines.
A slight amount of ‘give’ must be provided to secondary points and this may be by the
use of bungee cords (heavy elastic cord) or tying the rope from the ground mooring
point to the aircraft via a heavy weight (sack of sand). As the aircraft moves so the
mooring line has to lift the weight.
Fig. 12 PROPELLER HARNESS ATTACHMENT TO THE FUSELAGE
Fig. 13 PROPELLER TETHERING
blank
- 16 -
Fig. 14 MOORING THE SHORTS 360
Fig. 15 BLANKS & COVERS - SHORTS 360
blank
- 17 -
Fig. 16 TIE-DOWN DETAILS - SHORTS 360
JACKING & TRESTLING/SHORING
Aircraft are supported clear of the ground for manufacture and for maintenance
purposes. The equipment includes jacks, trestles, cradles, slings, gantries and
fixtures.
For maintenance purposes hydraulically operated jacks and trestles are usually
used.
Aircraft should be jacked on firm level ground in the hangar located in such a
position so as not to be in the way of other operations. If the aircraft has to be jacked
outside, the same applies but the AMM must be consulted as to the maximum
windspeed allowed and ATC contacted to find out the forecast weather conditions for
the period the aircraft is likely to remain on jacks.
The equipment to carry out a particular task is listed in the AMM as is the procedure
to be carried out. Some (large aircraft) aircraft are serviced in servicing docks and,
while the aircraft is supported, the area under the landing gear is lowered to leave the
aircraft supported clear of the ground. Most aircraft, however, are jacked up using
hydraulic jacks.
Trestles (Figure 17)
Usually used to support the aircraft after it has been jacked, but in some cases may
be used as a jack. They may be specially made or made up from various lengths of
‘angle iron’ joined together with nuts and bolts. They incorporate one or two jacking
heads which are adjustable by screw threads.
- 18 -
A padded metal or wooden beam is secured to the jacking head/s shaped to fit under
the wing or fuselage. Universal trestles can be supplied, so that using various
lengths of angle iron, trestles of different sizes, height, and breadth can be
constructed. The jacking heads will be common to them all.
Fig. 17 TRESTLES
Precautions
1. Check that the trestle and beam is of the correct type.
2. Check security of nuts and bolts.
3. Check screw jack threads for serviceability and lubricate.
4. Check padding and security of beam.
Lifting Jacks (Figure 18)
These are usually hydraulically operated to raise and lower the aircraft but for long
periods when the aircraft on jacks, support trestles are used in conjunction with the
jacks once the aircraft has been raised to the correct height. Types of jacks include:
* Pillar or bottle jack.
* Bipod.
* Tripod.
* Quadruped.
Hydraulic jacks can range in height from about 3ft (1m) to about 15ft (5m). Some of
the larger jacks may have an operating platform part way up the main body reached
by a fixed step ladder. Some of the larger jacks also have provision to be connected to
a central power supply so they can be power operated.
In general the jack comprises a central hydraulic unit around which are the support
legs. The moving pillar has either a screw thread and locking collar or a collar and
locking pin which enables the jack to be mechanically locked when the aircraft is at
the correct height. This prevents the collapse of the jack due to any fluid leakage. To
release the locking device the jack must be raised slightly to off-load the collar.
- 19 -
Fig. 18 LIFTING JACKS
Raising the jack is usually by means of a hand pump. The fluid control valve is
closed and the hand pump operated. This pumps fluid from the reservoir to the jack.
Some jacks may be controlled pneumatically from a central control panel. The air
release valve must be opened whenever the jack is raised or lowered to allow air
into/out of the top of the reservoir.
To lower the jack, raise it slightly, release the locking collar and slowly open the oil
control valve to control the speed of fall. The air release valve must be closed when
the jack is stationary and the oil control valve must remain closed when the locking
device is engaged.
An adapter head is fitted into the top of the pillar and this locates into a jack plate or
pad which is fitted, usually by pip-pins, onto the underside of the airframe (check
location in the AMM and painted on the airframe). The adapter and plate form a ball
joint which gives a degree of flexibility when raising and lowering the aircraft. The
bottom of the legs of the jack fit into plates with a ball socket joint to allow for any
slight unevenness of the ground.
It is essential that the plates sit firmly on the ground and that the legs are aligned
with a small recess in the plate socket to prevent binding.
When jacking ensure all legs are adjusted so that they carry equal weight, all pins are
fully in, and that the jack is vertical (some have a spirit level fitted).
- 20 -
Fig. 19 BOTTLE OR PILLAR JACK
Fig. 20 ARC LIFT
Jacks differ in their lifting capacity, size, number and composition of legs:
(a) Bottle or Pillar jack. Used for wheel changes or brake maintenance
where the jack is fitted to the landing leg (via an adapter) to raise the
aircraft sufficiently to get the wheel clear of the ground (figure 19). For a
flat tyre this height would be the depth of the tyre plus a small amount
for tyre clearance.
(b) Bipod. One of the legs of a quadruped jack is removed to leave two load
bearing legs and one adjustable support leg. This is used for arc lifts
where one side of the aircraft is significantly lower than the other (shock
absorber flat or flat tyre for example) (figure 20). The jack is placed so
that the two load carrying legs (lifting legs) are parallel to a line drawn
between the other main gear and the nose gear (or tail wheel).The jack is
angled against the third support leg so as to be at right angles to the
underside of the wing. As the lift progresses so the jack will straighten
through an arc with the support leg being continuously adjusted.
- 21 -
When the jack is vertical the lift stops and the other jacks are positioned
and a conventional jacking operation is carried out. This is a difficult
operation and is not often carried out. Always refer to the AMM
(c) Tripod. Three legs, equally disposed around the central body. Used for
vertical lifts only.
(d) Quadruped. Four legs, equally disposed around the central body. Two
are adjustable to allow for uneven ground. Used for vertical lifts only.
Larger jacks have transportation wheels fitted either permanently or temporary for
movement to and from the aircraft and can be towed – though very slowly. The
correct jack must be used (the maximum load is marked on the side of the jack) and
the correct adaptor and the aircraft should be raised and lowered slowing.
Servicing usually involves:
(a) Cleaning, lubrication and inspection for damage and corrosion.
(b) Checking oil level.
(c) All pins are in position and leg adjusting mechanisms work.
(d) Correct function of air and oil control valves.
(e) Correct operation of the jack and locking devices.
Jacking and Trestling a Nose Wheel Aircraft (Figure 21)
1. Consult the AMM for details of procedure, equipment used, position of
equipment, weight and C of G limits, fuel state, etc.
2. Check aircraft's C of G and fuel state.
3. Check aircraft is structurally sound to jack.
4. Configure the aircraft for jacking. Isolate appropriate electrical circuits
(pull C/B's). If this is not done the aircraft may think that it has taken
off and various services/warnings could operate.
5. Bond aircraft to ground.
6. Jack on firm level ground in the hangar or outside in a position so as
not to obstruct other aircraft movements. If jacking outside check wind
speed and direction with air traffic control and cross refer to the AMM.
7. Position ground equipment (one jack at the nose and one under each
wing – usually).
8. A person who knows what to do should be positioned at each of the
following:
(a) Each jack and trestle.
(b) Look-out for overhead obstructions (fin hitting the hangar
roof).
(c) Levelling station (plum-bob or spirit level on the aircraft to
check aircraft is being raised level).
(d) A person in charge to be in contact with all the others.
9. Chock the wheels (unless the manual states otherwise – the wheels of
levered suspension undercarriages will roll forward as the aircraft
raises, so check) and put brakes off.
10. Raise the aircraft slowly and keep in a level position, follow up with a
tail trestle. This is used to prevent the possibility of tail over balance.
- 22 -
11. At the required height lock all jacks and position steady trestles. These
may be at the tail, mid fuselage, wing tips and mid wing positions.
Consult the AMM and the positions are also painted on the aircraft.
Jacking and Trestling a Tail Wheel Aircraft
Many of the points mentioned for a nose wheeled aircraft apply here but the general
procedure is different and is usually as follows:
1. Chock the main wheels and ensure the brakes are off.
2. Weight the tail either by attaching weights to the tail wheel or placing
weights inside the rear of the aircraft. The author has seen sealed sacks
of sand used and stacked in the rear toilet on one aircraft. These
weights ensure that the aircraft does not tip forward on its nose.
3. Raise the tail of the aircraft manually (small aircraft), or by use of a
crane and special adapter in the main spare of the tailplane (the tail of
small aircraft are raised using a frame under the tail supported by a
cross-beam with two men either side the tail is raised manually).
4. Place a trestle under the tail, lower the aircraft onto it, and tie it down.
5. Place main jacks in position under each wing and jack until the wheels
are clear of the ground.
6. Place trestles as per the AMM.
Lowering the Aircraft
This will vary with each type of aircraft but in general it is the reverse of raising with
the following additional checks:
1. Consult the AMM.
2. Ensure the landing gear is complete, serviceable, and locked down with
‘three greens’ showing and ground locks fitted
3. Check wheels and tyres for serviceability and ensure tyres and shock
absorbers are correctly inflated.
4. Hydraulic system pressurised with landing gear locked down.
5. Wheel brakes are off and all unnecessary equipment and items clear
from under the aircraft.
6. All systems that require the aircraft to be jacked for testing have been
tested and cleared.
7. Stress panels are fitted.
8. Aircraft electrically/electronically configured for lowering (we don’t want
the spoilers deploying automatically for example).
9. Check aircraft loading and C of G.
Remove trestles and clear away from aircraft. Slowly lower the aircraft
to the ground keeping it level. This is done by releasing the lock ring on
each jack by 2 or 3 turns, opening the air release valve and slowly
opening the hydraulic control valve. The rate of descent is controlled by
this valve. When the jack ram lowers sufficiently to near the locking ring
then this is screwed up another 2 or 3 turns. This is a safety measure
so if the hydraulics was to fail the aircraft would only drop to the lock
ring.
- 23 -
10. When the aircraft is firmly resting on the ground and the jacking heads
are clear of the aircraft slide the jacks clear of the aircraft. Remove the
adapters from the aircraft (usually fitted with pip-pins and chock the
wheels.
Note. When removing the jacks from under the aircraft lower them clear of the
aircraft as quickly as possible as the aircraft oleos may stick and the aircraft might
‘jump’ down. Ensure hands are clear of the jacking head in case this happens.
With a tail wheeled aircraft the main jacks are lowered first; the main wheels
chocked; then the tail is lifted off its trestle, the trestle removed and the tail lowered
to the ground and all the weights removed.
Jacking and Trestling a Helicopter
This is similar to jacking and trestling a nose wheel aircraft and with helicopters
fitted with skids the amount of lift during a jacking operation is small as there is no
tyre deflection and little shock absorber deflection (there is some as the skid
structure is designed to flex to absorb shocks).
General
Remember to record and sign for all work carried out on the aircraft in the log book
or work cards – including jacking and trestling.
Note the jacking arrangements for the B757 in figure 21. Note the primary jacking
points and the secondary stabilising jacking point at the tail. Note the C of G range
and the Mean Aerodynamic Cord (MAC) length. For more details of these please refer
to the book in this series entitled Weight and Balance.
Fig. 21 EXAMPLE - JACKING THE B757
- 24 -
COLD WEATHER PRECAUTIONS
In some countries this is never a problem but in others, those in the northern parts
of the northern hemisphere and the far south in the southern hemisphere, frost, ice,
slush and snow can be a problem. In general:
1. Keep all working areas clear of snow and ice.
2. When spreading sand/salt outside in the working areas. Keep sand/salt
away from aircraft, aircraft equipment, jet intakes, Pitot static vents,
etc.
3. Ideally keep aircraft in heated hangers. Not always possible
4. Work in heated hangars/heated areas as much as possible. Personnel
must avoid getting too cold as this produces Cold Stress.
If it is not possible to work in a heated hangar or in close proximity to a
portable space heater then periods must be allowed at regular intervals
for the person to return to a heated area to be warmed through.
After Flight (Check the AMM)
1. Fit all airframe, engine and Pitot/static covers, and landing gear locks.
2. If aircraft is wet apply anti-freeze liquid to the inside of covers before
fitting.
3. Allow any ice in intakes, water drains, etc, to melt, drain water then fit
covers and plugs.
4. Drain oil whilst hot (from piston engines in particular in extreme cold),
and drain water traps in Pitot/static systems.
5. Drain drinking (potable) water systems.
6. Drain and clean all toilet systems.
7. Clean, drain and remove any foodstuffs from galleys.
8. Drain oil and water traps on pneumatic systems.
9. Park or moor aircraft – leave brakes off (prevents them freezing on).
10. Record all work done in the log book.
Before Flight (refer to AMM)
1. Remove covers, blanks and locks.
2. Remove ice and snow from airframe and engines using blower heaters
or fluid spray systems (see later chapters).
3. Pre-heat engines using blower heaters.
4. Fill any drained systems and check for leaks. Piston engines are usually
filled with pre-heated oil (in extreme cold conditions).
5. Check all heaters – windscreen – Pitot – TAT – drain masts – ice
detectors – EPR – heater mats etc.
6. Carry out normal before flight inspection.
7. Ensure all engine intakes are clear of snow/ice deposits. Rotate
fan/turbine with wooden stick to check freedom of movement.
8. Check that all control surfaces, flaps, slats, spoilers, landing gear
mechanisms, airframe, all air vents and probes, intakes, exhausts etc
are clear of frost and snow deposits.
9. If aircraft does not fly within a certain time (depending on ambient
temperature) re-do items 2, 3 and 7 above.
- 25 -
ICE & SNOW FORMATION ON AIRCRAFT
Icing on aircraft is caused by a combination of freezing conditions (low ambient
temperature or low outside air temperature (OAT) and moisture in the atmosphere. It
may also be caused by freezing rain or drizzle. The actual amount depends on
surface temperature, surface condition, duration of icing conditions, and the amount
of moisture present in the atmosphere.
Hoar Frost
Hoar frost occurs on a surface which is at a temperature below the freezing point of
the adjacent air and, of course, below freezing point. It is formed in clear air when
water vapour is converted directly to ice and builds up into a white semi-crystalline
coating. Hoar frost is white, soft and feathery.
When hoar frost occurs on aircraft on the ground, the weight of the deposit is
unlikely to be serious, but the deposit, if not removed from the airframe, will interfere
with the airflow causing drag and possibly preventing it attaining flying speed during
take-off. The windscreen may be obscured, and the free working of moving parts such
as flying control surfaces may be affected.
Remove all frost deposits from the aircraft before dispatch.
Rime Ice
This ice formation, which is less dense than glaze ice but more dense than hoar frost,
is an opaque, rough deposit. At ground level it forms in freezing fog conditions and
consists of a deposit of ice on the windward side of exposed objects. Rime ice is light
and porous and results from the small water drops freezing as individual particles,
with little or no spreading. A large amount of air is trapped between the particles.
Aircraft in flight may experience rime icing when flying through clouds with the air
temperature and the temperature of the airframe below freezing point; the icing
builds up on the leading edge, but does not extend back along the chord. Ice of this
type usually has no great weight, but the danger is that it will interfere with the
airflow over wings, etc, and may choke the orifices of the carburettor, air intakes and
Pitot-static vents.
Glaze Ice
Glaze ice is the glassy deposit that forms over the village pond after a frosty night. On
aircraft, glaze ice forms when the aircraft encounters freezing rain with the air
temperature and the temperature of the airframe below freezing point.
It consists of a transparent or opaque coating of ice with a glassy surface and results
from the liquid water flowing over the airframe before freezing; glaze ice may be
mixed with sleet or snow. Glaze ice is dense, tough and sticks closely to the surface.
It cannot easily be shaken off and, if it breaks off in flight it comes away in lumps
which can cause damage to the airframe.
- 26 -
The main danger of glaze ice is aerodynamic and debris damage, but to this must be
added, that due to the weight of ice, unequal wing loading and propeller blade
vibration may occur. Glaze ice is the most severe and the most dangerous form of ice
formation on aircraft.
Debris Icing
This is caused by slush/snow/moisture being throne/blown onto the aircraft by the
wind, or passing vehicular traffic or blown by propeller/jet efflux from other aircraft.
Pack Snow
Normally, snow falling on an aircraft does not adhere and will settle on the top
surfaces only. If the temperature of the airframe is below freezing point however,
glaze ice may form from the moisture in the snow. The icing of the aircraft in such
conditions, however, is primarily due to water droplets, though snow may
subsequently be embedded in the ice so formed.
Conclusions
If any ice or snow on aircraft is not removed before take-off then the following may
result:
(a) Decreased lift due to aerofoil change in shape. An ice layer 1/16th of an
inch (1.6mm) thick on the leading edge can reduce lift by up to 24%.
(b) Increased drag due to the rough surface of the airframe (skin friction).
(c) Decreased propeller efficiency due to alterations of the blade profile and
increased blade thickness.
(d) Propeller vibration due to uneven distribution of ice.
(e) Loss of control due to ice preventing movement of control surfaces.
(f) Increased risk of control surface flutter due to control surface
C of G change because of the ice.
(g) Increased aircraft all up weight and increased wing loading. The weight
of the ice may prevent the aircraft from taking-off.
(h) Higher stalling speed.
(i) Loss of inherent stability may occur due to displacement of the centre of
gravity caused by the weight of ice.
(j) Loss of vision if the windscreen becomes iced over.
(k) Ice debris damage.
(l) Malfunction of flight/engine instruments. This would occur if
Pitot/static and EPR probes/vents became blocked.
GROUND DE-ICING
The aircraft de-icing systems are designed to remove or prevent the formation of ice
on parts of the wings, tail, engine nacelles and various probes during flight and
would not normally be effective in removing deposits which have accumulated while
the aircraft is stationary. Their use may aggravate the situation by melting some of
the deposit which would then freeze elsewhere.
- 27 -
The use of cabin/airframe heating to remove deposits from the fuselage/wings etc is
not recommended. So ground de-icing by the ground crew must be carried out if
there are any deposits on the aircraft.
When aircraft are kept in a hangar during inclement weather any melted snow or ice
may freeze again if the aircraft is subsequently moved outside into sub-zero
temperatures. Complete protection could be provided by placing aircraft in heated
hangars, but for large aircraft this is not always possible except for servicing.
ICE & SNOW REMOVAL
In general, depending on ambient temperatures, ice deposits can be removed from
the airframe/engines using:
* Cold water (ambient temperatures above freezing).
* Hot air.
* Hot water (ambient temperatures above -3°C). Max water temperature
82°C (180°F) followed by de-icing fluid (rare).
* De-icing fluids(common)/de-icing pastes.
Hot air blowers are powered electrically or by the use of fuel and are very effective for
smaller aircraft. For larger aircraft their use is limited to local area warming for work
purposes.
For most aircraft ice is best removed by the use of de-icing fluid (eg DTD 406 or
similar, or, in severe conditions, Kilfrost ‘Arctic’ or equivalent).
These fluids normally contain ethylene glycol and isopropyl alcohol and may be
applied either by spray or hand. It should be applied as close to the departure time
as possible and repeated if aircraft departure is delayed.
De-icing fluids may adversely affect glazed panels, composite structures or the
exterior finish of aircraft, particularly when the paint is new. Only the type of fluid,
and it’s method of application, as stated in the AMM should be used.
Some fluids, particularly those with an alcohol base, may cause dilution of oils and
greases. Spray nozzles should not therefore, be directed at lubrication points or
bearings and an inspection of areas where fluid may be trapped is necessary. The
AMM may specify re-lubrication in these areas whenever de-icing fluids are used.
Frost and ice may also be removed from aircraft surfaces using a mobile hot air
supply. The air is blown on to the wings, fuselage and tail surfaces and blows
away/melts the ice. Operators using this equipment should ensure that any
meltwater is dried up and not allowed to accumulate in hinges, structure etc, where
re-freezing could occur.
When using hot air blowers, remember that the air can heat some polymers (plastics)
to near melting point, can melt greases out of bearings and may even over-heat some
aluminium alloys (if prolonged close exposure is allowed). Exercise care when
directing the hot air stream so as not to give prolonged exposure to these areas as
well as to any inflammable liquids.
- 28 -
Soft laying snow can be removed from the top surfaces of the aircraft with a long
handled brush or squeegee, care being taken not to damage aerials, vents, stall
warning vanes, vortex generators, etc, which may be concealed by the snow. In at
least one aircraft manual the procedure for snow removal on top of the fuselage is to
use a soft rope thrown over the fuselage and pulled to and fro and backwards over
the fuselage. Again the same precautions should be observed re aerials, stall warning
vanes, vortex generators etc.
Snow should be brushed off the aircraft structure and should not be allowed to go
into cowlings, intakes, vents, shrouds etc. Light snow can be removed by blowing
with cold air. It is important to remove the snow from around the aircraft and keep
the working area clear. Should snow and ice be allowed to accumulate on the ground
it will make working in the area difficult, cause obstruction and may be sucked into
intakes.
Remember, when walking on the surface of the aircraft it is slippery at the best of
times. When there is snow about then the aircraft surface can be treacherous to walk
on. Always use a safety harness or tackle the job from a set of steps or a gantry.
Fluid Sprays
Fluids may be used hot or cold and are of two main types:
Type I AEA fluid (unthickened). Has a high glycol content and a low viscosity.
Good de-icing but has short ‘hold-over times’.
Type II AEA fluid (thickened). Has a minimum glycol content of 50%. Good de-
icing with longer ‘hold-over times’.
The above classifications are fairly old and some (modern) aircraft manuals make
mention of type I, II, III and type IV fluids. For example, type II and IV fluids are used
when:
Temperature down to (°C) Dilution ratio by volume (de-icing
fluid/water)
-3 50/50 (Type I fluid used neat also.)
-14 75/25
-25 100/0
below -25 Insure ambient temperature at least 7° higher
than freezing point of de-icing fluid.
Ice and frozen snow deposits can be removed by fluid spraying. It is important to
ensure that all surfaces are de-iced including all airframe external surfaces
(including wings, tailplane and fin); control surfaces; high lift devices; spoilers;
propellers; rotorblades (on helicopters); windscreens; engine intakes; ram air and
other intakes; landing gear up and down locks; fluid drains; Pitot and static probes;
EPR probes; TAT probes; A of A vanes etc.
- 29 -
In general do not direct the fluid:
(a) Into the wheel brakes.
(b) Into control surface shrouds and structure openings.
(c) Into Pitot/static vents, TAT probes, EPR probes, drains etc.
(d) Onto windscreens and transparent panels - in some cases
delamination may occur (if fluid incompatible, use approved windscreen
de-icing fluid).
(e) Into air intakes and exhausts - engines and air-conditioning systems.
(f) Into fuselage vents/drain holes.
(g) Into bearings and greased mechanisms.
(h) Close to the structure or other equipment, particularly if the fluid
spray is high pressure - it could cause damage and erosion.
In general always:
(a) Consult the AMM.
(b) Remove heavy deposits of snow symmetrically about the aircraft
longitudinal and lateral axes so as to prevent possible overbalance.
(c) Blank off Pitot/static vents, intakes and exhausts and vents and
drains where possible.
(d) Ensure the aircraft is completely snow and ice-free. Some manuals allow
a small amount (depth specified) of ice on the underside of the wing and
some hoar frost on the top of the fuselage. Check the AMM.
(e) Carry out a visual inspection after removal to check for (d) above, check
structure for impingement damage and ensure that fluid has not entered
into areas where it should not be, eg:
* Probes – pressure and temperature sensing.
* Structure drains.
* Brakes.
* Structure.
* Drain masts.
* Normal and emergency exits.
* Cargo doors.
* Windows and windscreens (through vent holes etc).
* Inspection panels.
* Control surface shrouds.
* Control surfaces.
* Air conditioning intakes/exhausts.
* Engine intakes/exhausts.
(f) Record and sign for the work done in the aircraft log book. Record the
fluid used, the dilution ratio, the date and time of application, the fluid
temperature and the ambient temperature.
(g) Monitor the aircraft and the ambient temperature and if the
temperature drops then consider re-de-icing the aircraft, or if the
aircraft does not take off within the Hold Over time allowed then re-de-
ice.
- 30 -
Table from CAP 512 (now withdrawn)
TABLE 1 GUIDE TO HOLD-OVER TIMES
After de-icing the fluid will have a period during which time it will remain effective -
depending on ambient conditions. It is important to read the fluid manufacturer’s
instructions regarding this ‘hold-over time’ and to re-treat the aircraft if the aircraft
does not take-off within the time period.
If in doubt about the ‘hold-over time’ re-treat the aircraft prior to departure anyway.
In general, fluid sprays may be applied cold or hot (hot is the best) and may be low
pressure or high pressure (about 100psi).
Do not exceed the pressure and temperature stated in the aircraft manual, and do
not put the fluid nozzle too near the structure to reduce the possibility of
impingement damage.
Table 1 gives some idea of hold-over times, but it is important to remember that it is
only a guide. You should at all times consult the de-icing fluid manufacturer’s
literature/AMM.
Jet Engines
Jet engine icing can occur if the ambient temperature is less than 10°C (50°F) and
there is visible moisture present such as fog, rain, sleet or snow.
- 31 -
For ambient temperatures down to -30°C (-22°F) the engines can normally be started
without any additional precautions – other than making sure intakes, exhausts,
inlets, outlets and probes are clear of snow and ice. The fuel control is set to RICH
and the oil pressure is likely to read high and the quantity indication likely to read
lower than normal for the first few minutes of running. After this period the values
should normalise.
It the aircraft is taking off the engines should idle for a minimum period of 5 minutes
to allow the engine to warm through. If the engines are just being started to warm
through then they must run for a minimum period of 10 minutes.
If the ambient temperature is lower than -40°C (-40°F) then the engine core must be
pre-warmed for a period of time using hot air blowers (max air temperature 121°C
(250°F). Damage will occur to the bearings otherwise as the oil viscosity will be too
high to allow it to flow. The process will take some time for the core to properly heat
through.
Piston Engines
In very general terms similar conditions apply as to jet engines. It is common at very
low temperatures to drain the oil immediately after engine shut-down. The engine is
pre-warmed before start-up. The oil is pre-warmed before being put back into the
engine and the engine started immediately.
Fluid spray equipment may be:
(a) A bucket and hand operated pump – for small aircraft.
(b) A trolley with a tank and an air pressure supply.
(c) A motorised vehicle with heated pressurised tank and a hydraulically
operated boom spray nozzle. These are operated by specially trained
personnel (normally a driver and boom operator) but it is your aircraft
and you must sign for the work done.
(d) A fixed gantry spray system (car wash system) that the aircraft is towed
through (or taxis through – check engine operation under these
conditions) for those airfields that suffer prolonged icing conditions
during winter.
Hot Fluid Spray
Heated to about 82°C (tank temperature), the heat also has a part to play in removing
the ice so is better than cold fluid spray. Because the fluid is not diluted by the ice
quite so much as the cold fluid spray, it also is better than the cold fluid spray in
preventing further ice formation.
If a ‘car wash’ system is used it is important to note that the fluids used must be
non-toxic and diluted enough to ensure that they are not a fire hazard (hot exhausts
etc). When taxiing through, all cabin conditioning air vents/engine tapings should be
off – to minimise de-icing fluid fumes in the aircraft.
- 32 -
Anti-icing
(Anti-icing is the prevention of ice build-up and De-icing is the removal of ice
deposits).
The above systems will prevent ice formation building up for a time. This depends on
ambient conditions of course. The hot fluid spray being better at this than the cold
fluid spray. However, there is a special dual purpose spray that is much better at
anti-icing than either the cold or hot fluid systems.
This anti-icing barrier compound is mixed with water (check manufacturer’s
instructions) and sprayed at a temperature of about 80°C when used as a de-icing
fluid. When used for anti-icing the fluid is sprayed onto the aircraft cold and
undiluted either before the onset of icing conditions or immediately after the aircraft
has been de-iced. A film of anti-icing compound is left on the sprayed surfaces which
prevents the formation of further ice deposits (depending on ambient conditions).
When used as a de-icing fluid it may give protection from freezing for up to 2 hours.
When used as an anti-icing fluid it will give protection for longer periods - but check
the ambient conditions.
On some aircraft not equipped with an aerofoil de-icing system the use of a de-icing
paste may be specified. This paste will prevent the accumulation of ice deposits.
When spread smoothly by hand over the leading edges of the wings and tail unit the
paste presents a chemically active surface on which ice may form but cannot bond.
Any ice which does form will be blown off in the airflow.
The paste should be reactivated before each flight in accordance with the
manufacturer’s instructions and replaced after approximately four flying hours.
De-icing pastes do not constitute an approved method of de-icing when approval for
intentional flight into icing conditions is required.
Table 2 shows an extract from an AMM. It is interesting to note that cold water is
recommended for ice/snow removal if the ambient temperature is above 1deg C. The
engineer should check that ground temperatures are also above 1deg C and that
forecast temperatures are set to rise.
blank
- 33 - SNOW FROST ICE
A Ambient temperature
34deg F (1deg C) or above
B Ambient temperature
27deg F (-3deg C) to 34deg F (1deg C)
C Ambient temperature
below 27deg F (-3deg C)
1
COLD WATER
USE
NOT ALLOWED
NOT ALLOWED
2 HOT
WATER (200deg F 93deg C)
followed by de-icing fluid.
USE
Optional to apply de-icing fluid.
USE
NOT ALLOWED
3 DE-ICING FLUID
(200deg F)
NOT RECOMMENDED ON COST GROUNDS
USE
USE
4 ANTI-ICING
FLUID
NOT RECOMMENDED ON COST GROUNDS
Apply after method 2 to keep ice, frost & snow to a minimum. Apply after method 3 if necessary.
Apply as protection if
ice, snow or frost expected.
Table 2 EXAMPLE TAKEN FROM AN AMM
REFUELLING/DEFUELLING
Refuelling is the filling or partial filling of some or all of the aircraft tanks and
defuelling is the removal for the fuel from those tanks (normally for maintenance
purposes).
Refuelling is normally carried out at the end of each long flight. The amount of fuel
uplifted depends on the operational requirements. With some aircraft all tanks are
filled completely whilst on others the uplift requirement and tanks to be filled will
depend on the duration of the next flight.
Refuelling systems can be categorised into two groups:
* Open orifice refuelling (over-wing, open vent or gravity refuelling).
* Pressure refuelling, under-wing refuelling or closed line refuelling.
Open Orifice Refuelling
This method of fuelling an aircraft is similar to the way most road vehicles are fuelled
on the garage forecourt. It is common on small aircraft and some larger aircraft have
the facility as well as a pressure refuelling system.
- 34 -
On the top surface of the wing (or fuselage in some cases) there is a filler cap and
tank opening. After operating the quick release fastener and opening the refuelling
panel the refuelling cap is unscrewed from the tank. In figure 22 the refuelling cap is
fitted flush with the wing surface and lifting the tab on the cap allows the cap to be
removed (by twisting the tab or operating a lever).
The filler port may be connected to pipework delivering the fuel to all tanks or, more
often, directly into the individual tank. The cap is usually connected with a lanyard
to the structure to prevent loss and there is usually a bonding point.
To refuel, the fuel nozzle from the bowser is bonded with its bonding lead to the tank
and the nozzle placed inside the tank orifice. The nozzle lever is operated to allow fuel
to flow into the tank. Care needs to be exercised as the tank starts to get full, as it is
a high delivery rate and the fuel will spray back out of the tank when the tank
becomes full. Towards the end of the filling operation flow rates should be reduced
and preparation made to shut-off the control handle on the refuelling hose quickly.
In addition care is needed when opening the refuelling cap to prevent contamination
of the fuel – by rain (if raining) or by debris such as sand etc, if a gale is blowing.
Other potential pitfalls include the danger of walking on the top surfaces of wings
and the possibility of damage to the wing from filler caps, fuelling hoses, people’s
shoes etc. Also there is a risk of fuel imbalance between the tanks (port and
starboard wing tanks for example).
After refuelling the bonding lead should be disconnected and the cap closed.
The biggest disadvantage is that of time to refuel. Access to the top of the tanks can
be difficult and may require step ladders, high rise platforms etc and the actual filling
process can be slow.
Most small aircraft only have the one method of refuelling – gravity refuelling, but
most larger aircraft have both systems fitted. The B747, for example, has the option
of over-wing fuelling, but using this method would require up to 8 hours to fill the
aircraft.
Over-wing refuel points on large aircraft are rarely used but if the aircraft has landed
at an out-station which does not have pressure refuelling equipment then they can
become very useful. Some aircraft are not fitted with them at all, eg the B777.
Pressure Refuelling
This is a system of refuelling where fuel under pressure [max about 50psi (345kPa)]
is supplied from a bowser, tanker, or refuelling pumping vehicle. (It is common at
large airports to have the fuel pumped underground. A pumping vehicle connects into
the ground connection (after lifting a steel cover plate) and pumps the fuel into the
aircraft tanks. The bowser’s (fuel tanker)/pumping vehicle’s fuel hose is connected to
the refuelling point of the aircraft via self sealing connections, both on the aircraft
and on the hose (figure 23). From this single point there is a pipework system within
the aircraft connected to all the tanks in the aircraft. The fuel is controlled into each
tank (by a computer on modern aircraft) by energising solenoids within the refuel
valves, float valves etc.
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Fig. 22 OVER WING FUELLING POINT
As each tanks becomes full so its refuel valve shuts off and when all tanks are full
refuelling ceases.
Advantages of pressure refuelling include:
* Higher pressures and flow rates and shorter fuelling times.
* Less risk of spillage.
* Ability to fill individual tanks with any desired quantity of fuel using the
aircraft’s on-board refuelling control system. Electrically or computer
controlled.
* Reduced risk of fuel contamination.
* Better access. Fuelling points are on the underside of the wings and
accessed from the ground.
* Reduced fire risk.
Refuelling Operation
Check the AMM.
The electrical power supply must be ON to operate the various valves, indicators,
refuelling panel and computers etc. This can be provided from the aircraft 400Hz
supply or even from the aircraft battery. Usually power to the refuelling systems is
removed when the aircraft becomes airborne, preventing inadvertent fuel transfer in
flight. The refuelling panel is usually located at the refuelling point and usually
within easy reach of the ground (figure 24).
With power available, and the refuel panel door open, the indications on the refuel
panel will show (the system may go through a BITE check first).
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Fig. 23 PRESSURE REFUELLING CONNECTION
The dust cap is removed from the refuelling point and from the hose connector. The
aircraft bonding clip is connected to the refuelling hose and the hose connected to the
aircraft fuelling point via the quick release bayonet type connector.
The action of connecting the hose to the aircraft opens both the valves on the aircraft
refuelling point and the fuelling hose.
When the bowser starts pumping, the pressure will open the non-return valve and
fuel will flow into the system that supplies all the tanks (sometimes called a fuelling
gallery).
As the fuel flows into each tank so a fuel quantity measuring system will measure the
amount of fuel in the tank. The fuel will be shut off to the tank by an electrically
operated shut-off valve when:
(a) The tank becomes full, or
(b) When the fuel reaches the level (quantity) as selected by the engineer at
the refuelling panel.
The fuel flow will continue into the aircraft system until all tanks are full or have
reached their selected quantity level. The bowser/pumping vehicle operator will then
switch the pumping operation OFF.
The system may have provision to allow all tanks to be filled at the correct rate.
However, care still needs to be exercised to ensure an imbalance doesn’t develop (for
example, more fuel on one side of the aircraft than the other would up-set the
aircraft’s C of G laterally).
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Fig. 24 REFUELLING CONTROL PANEL
Sometimes additional refuel points are provided to increase the speed of the fuelling
operation – so more than one bowser/pumping unit can be used simultaneously.
Refuel valves can be mechanically operated but they are normally solenoid operated,
using the fuel pressure to actually operate them open. This type of refuelling requires
overfill protection to prevent tank rupture or fuel spillage.
Also, with some aircraft care has to be taken when refuelling /defuelling so as not to
put the longitudinal C of G outside the range between the main gear and the nose
gear.
The aircraft’s C of G, for a nose wheeled aircraft, is just forward of the main gear and
with some aircraft with highly swept wings it might be possible to fuel some tanks in
the wings such that the C of G is moved aft passed the main gear – this would cause
the aircraft to tip back onto its tail.
For tailed wheeled aircraft the C of G is behind the main gear and the tanks are so
situated so that it is not normally possible to overbalance the aircraft forwards.
Defuelling
For overwing refuelling type aircraft this is usually carried out using drains situated
at the bottom of the tanks. For some aircraft the system can be drained from the
engine supply connection (check the AMM).
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The fuel is drained into cans (suitably bonded) and returned to the fuel supplier
suitably marked as contaminated to be filtered and re-used.
For pressure defuelling aircraft a bowser in connected (with defuel selected), the non-
return valves are de-seated and the defuel handle is turned. On newer aircraft this
may be a switch selection on the refuel panel. This connects the engine feed manifold
to the refuel points. The engine fuel feed boost pumps are used to provide fuel to the
engine feed manifold and through the defuel valve to the bowser.
Once the bowser has positive flow the pumps on the bowser can be selected to suck.
Again, consideration has to be given as to where fuel is being taken from on the
aircraft to prevent imbalances developing.
Precautions
Fuel is highly combustible and fuel flow will cause a build up of static electricity –
which could cause a spark if the correct bonding has not been carried out.
The following precautions should be observed (also check the book in this series
EASA Module 7 entitled Safety):
* Ensure the correct grade of fuel is used. Check the AMM, also indicated
at the refuelling point and marked on the bowser/ground refuelling
point. (For the mechanical engineer see also the books in this series
EASA module 15 for jet fuels and 16 for gasoline and Diesel fuels).
Check the bowser driver’s log book to ensure that the required dip
checks/water drain checks (quality control checks) have been carried
out on that particular batch of fuel. This will also indicate the specific
gravity of the fuel.
* Bonding. The aircraft needs to be bonded to earth, ideally through a
purpose built bonding line but CAAIPs state alternatives for ‘field’
operations. The bowser must also be bonded to earth and this is often
done through the tyres or a bonding chain/lead hanging underneath.
The bowser and aircraft are bonded together by a bonding lead being
reeled out from the bowser to the aircraft and connected to the aircraft
earth point, which is often (but not always) near the refuel point. The
refuelling hose is bonded to the aircraft.
* The aircraft (and bowser) must be in a designated refuel zone that
should contain any spillage (minimum 20ft or 6m radius).
* No smoking, naked lights or unauthorised equipment allowed. NO
SMOKING signs displayed 50ft (15m) distance from the outermost tank
vent.
* Aircraft power should not be connected or disconnected during the
refuel process. APU’s, if running, should be left running for the duration
and should not be started or stopped during this time.
* Ensure fire cover is available - provided by the airport fire service or
through individual hand held CO2 or Dry Power extinguishers.
Refuelling should not be performed in a hanger unless additional fire
cover is available.
* No radio or radar transmissions allowed during the operation.
* No refuelling during an electrical storm.
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* Check that there is clearance under the aircraft from any ground
equipment as the aircraft will settle.
* Aircraft engines should not be running. Some exceptions are allowed to
this rule such as some helicopter operations.
* All vehicles should be parked such that they have a clear exit path – in
case of fire.
* Keep all connections, maintenance areas and equipment clean to
prevent the possibility of fuel contamination. Avoid spillage.
* Any engine driven ground equipment that is required should be cleared
to run in fuelling areas (spark proof exhausts etc) and parked as far
away as possible from the actual refuelling operation.
* If any portable electrical equipment is to be used (torches etc) then
these must be of the approved safety type).
* No flash photography within 20ft of filling points or vents. Do not use
mobile phones of any other personal electronic equipment.
* All combustion heaters must be OFF. Some older aircraft have these.
* Complete the bowser operator’s record of fuel taken or received by the
bowser (gauges at the refuelling control station on the bowser). Compare
these values to those of the aircraft system gauges. Dip tanks if
necessary (a very accurate method of ascertaining the quantity of fuel in
each tank).
* Record fuel up-lift or fuel removed in the aircraft log book and sign.
Draining
This may be required if access is required to the fuel tanks or for certain
maintenance operations such as tank removal.
While defuelling will remove nearly all of the fuel it is often necessary to remove the
residual fuel in each tank using the drain valve/port.
Drain ports are also used for taking fuel samples.
Figure 25 shows a typical drain valve. They are located at the bottom of the fuel tank.
For fuel sampling the primary poppet is pushed up, this de-seats the valve and
allows the fuel from the bottom of the tank to drain into a container.
Fig. 25 TYPICAL DRAIN VALVE
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Fuel Spillage
Clear-up all fuel on the aircraft and on the ground. If a major spillage occurs
evacuate all personnel, try and stop the fuel flow, and call the fire services. Do not
start aircraft engines or vehicles until all fuel has been cleared from the area.
Do not allow fuel into drains, waterways etc. If this does occur inform the local water
authority and follow their advice.
Fuel can be mopped up using fuel absorbent agents or emulsion compounds.
These should be disposed of in accordance with the local authority regulations.
All tools and equipment used are to be flame proof and/or spark proof.
AIRCRAFT CLEANING
By aircraft cleaning we do not mean the domestic cleaning of the cabin after the
passengers have left the aircraft but the cleaning of the structure/components either
as a routine procedure or after a spillage of some kind.
For some operators the job of aircraft cleaning is contracted out so the engineer
normally does not get involved – except for checks and inspections afterwards. For
other operators the aircraft engineers have to do it all. In either case, you as the
engineer are expected to know how to go about things. As far as the syllabus is
concerned it is not clear whether this applies only to the B1 person so if you are a B2
person it would be advisable to, at least, read through the subject – particularly
battery electrolyte spillage . The responsible engineer would be required to know:
* The materials to use.
* The precautions to be taken.
* The processes to be carried out.
* The checks and inspections to be carried out afterwards.
External cleaning is carried out:
* As a routine measure to keep the aircraft ‘looking good’ and to help
reduce aerodynamic drag. The airframe will get naturally very dirty over
a period of time and dirt increases skin friction and drag.
* To help prevent deterioration/corrosion as a result from dirt build-up.
* As a routine measure when carrying out certain operations where
fluids/chemicals might contaminate the airframe. Such as alighting on
sea-water (float plane, sea plane etc), crop spraying/ dusting, or flying
in a corrosive atmosphere (low level over the sea, for example).
* As part of a rectification procedure when something goes wrong and
fluids are spilt. For example, chemical fluid spillage, hydraulic fluid
spillage, battery electrolyte spillage, mercury spillage, leaks from toilets
etc.
The aircraft as a whole and its component parts should be kept clean. This helps to
reduce wear, allows for leaks to be more readily detected, reduces crevice corrosion
and makes the aircraft more aerodynamic (for surface cleanliness anyway). It also
helps to promote a good image to customers – and makes the aircraft more pleasant
to work on.
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For general exterior cleaning a non-acid soapy solution diluted in water can be used
and the area rinsed off with clean water and dried. Turco Air Tech (or similar) is
suitable.
Materials
Various cleaners are available including Teepol, Turco Air Tec, Ardrox 6025 and PD
680. They all meet various MIL specifications and should be used in accordance with
the cleaning manufacturer’s instructions and the AMM.
These are all listed in Chapter 20 of the AMM.
Table 3 shows part of a listing from an aircraft manual. There is no need to commit
the details of any of these materials to memory but reading through the table does
give you some idea as to the range available.
In this book we will deal with the following episodes but always check the AMM
Chapter 51 for specific cleaning instructions. Cleaning after:
* Chemical crop spraying/dusting.
* Salt water contamination.
* Toilet water leakage.
* Hydraulic fluid contamination.
* Battery acid spillage.
* Mercury contamination.
The procedure to be followed will depend on the actual contaminant and the extent,
but in general terms:
1. Refer to the AMM Chapters 20 and 51.
2. If components are affected, remove for cleaning.
3. If control cables or carpets are affected they are replaced.
4. Inspect area after cleaning.
5. Refit components removed and any systems disturbed are tested.
6. Details of the work carried out are recorded in the log book and the
work signed for.
AFTER USE AS A CHEMICAL CROP SPRAYER
Refer to the aircraft manual for cleaning/inhibiting the powder-hopper/spray-tank
and the distribution system (if needed), also for the cleaning of the external
airframe/engines. Refer to the liquid chemical/powder supplier manual (or check on
the instructions on the containers) for any special cleaning instructions/safety
precautions.
If the aircraft is to be washed, check with the local authority responsible for the
drainage system that wash-water is acceptable going into the drains. If it is not
acceptable wash-water must be collected in tanks and removed by a specialist
chemical disposal firm.
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DESIGNATION SPEC USES
Aircraft exterior Turco Air Tec USA (MIL-C-087936)
General purpose aircraft exterior cleaner.
Liquid detergent concentrate Ardrox 6025 USA (MIL-C-87936)
Cleaner and stain remover.
Varsol/white spirit UK USA
Cleaning solvent for mechanical parts.
Trichloroethane (Methyl chloroform)
Genklene USA
Cleaning solvent.
Trichlorotrifluoroethane FreonTF Cleaning oxygen system pipe lines.
Isopropyl alcohol Air3660 France USA
General cleaning.
Rain repellent cleaner Altupol Cleaning rain repellent off windscreens.
Safety solvent USA Odour free solvent cleaning agent.
Stain remover Teepol (MIL-D-16791)
Dry cleaner PD 680 (BS 245:76 type 1)
Solvent for cleaning mechanical parts.
Plastic polishing compound (fine grade)
PP-560 USA
Paste for polishing Plexiglas.
VDU cleaner Alglas V Anti static flight-deck CRT screen cleaner.
TABLE 3 – CLEANING AGENTS
Various cleaning agents are listed in the AMM for both general cleaning and
specialist cleaning. All are supplied with user instructions and health warnings
where necessary.
Always keep all fluids/powders off the skin. Ensure they are kept out of the eyes and
are not breathed in. Wear protective clothing, eye protection and breathing apparatus
where specified in the chemical manufacturer’s manual.
For general exterior cleaning a non-acid soapy solution diluted in water can be used
and the area rinsed off with clean water and dried. Turco Air Tech (or similar) is
suitable.
- 43 -
Clean all air filters (carburettors intakes and air conditioning intakes etc.). Ensure all
water traps are drained and cleaned (Pitot static systems, pneumatic systems etc.).
After airframe cleaning move aircraft to a dry area and check all aircraft drains to see
that they are clear and make sure water/cleaning liquid has not entered parts of the
airframe such as:
* Engine intakes and exhausts.
* Pitot static vents etc.
* Windows, doors and hatches.
* Air conditioning vents.
* Cooling grills.
* Drain holes.
Glass windscreens can be washed with a non-acid soapy solution and cleaned with a
chamois leather and plastic windows can be washed with the same solution and
cleaned with a fine grade plastic polishing compound (listed in the AMM).
Inspect all surfaces and external components for corrosion/erosion and rectify any
damage found as per the aircraft manual (SRM).
Ensure all control surfaces have full and free range of movement.
Record details of the work carried out in the aircraft log book and sign CRS.
After airframe cleaning check all drains to see that they are clear and make sure
water/cleaning liquid has not entered parts of the airframe such as:
* Engine intakes and exhausts.
* Pitot static vents etc.
* Windows, doors and hatches.
* Air conditioning vents.
* Cooling grills.
* Drain holes.
SALT WATER CONTAMINATION
Flush area affected with clean water. Wash area with cleaning agent as specified in
Chapter 51 diluted with water. Rinse again and dry with warm air. Inspect the area
for corrosion/damage and repair as laid down in the manual.
TOILET WATER CONTAMINATION
Does not happen often and when it does it is usually because of an incorrectly seated
valve or a pipe/union leak, or toilet overflowing – on older toilet systems.
Wear protective clothing including goggles.
Find source of leak and rectify.
- 44 -
Remove as much liquid as possible using a cloth or a liquid certified vacuum cleaner.
Remove and discard carpets etc. Thoroughly wash area using a mixture of 100g of
Bicarb of Soda to 1 litre of water. Rinse area and dry. Inspect area to see that all
contaminants have been removed, is corrosion free and all anti-corrosive treatments
are in place. Fit replacement soft furnishings.
HYDRAULIC FLUID CONTAMINATION
Wear protective clothing. Rectify source of leak.
Mop up as much of the fluid as possible. Apply cleaning agent as recommended in
Chapter 51 (in some cases after application it must be left to 30 minutes). Flush with
clean water and dry with air dryer. Inspect area to see that all fluid has been
removed and check that electrical insulation, rubber and plastic items etc have not
been contaminated. If they have, change.
If hot hydraulic fluid (above 132°C) has leaked onto titanium then embrittlement will
result.
The fluid may leave a light brown/dull black residue. Remove this using acetone and
a wooden/plastic scraper. If the protective paint has been damaged or the metal has
been contaminated then the part must be replaced.
BATTERY ELECTROLYTE SPILLAGE
In the event of electrolyte spillage in the aircraft, the following action must be taken
immediately.
Rubber gloves and protective clothing must be worn and use eye protection.
1. Check (and rectify) the cause of the spillage. Check the battery – if suspect,
change. Remove the battery for access.
2. Remove all pools of electrolyte by mopping with a clean rag moistened with
water, care being taken to prevent spreading of the electrolyte. The rag
should be frequently rinsed out in water to remove electrolyte during this
process.
3. Provided the electrolyte has not become trapped in any structure, rinse the
area with clean, cold water, taking particular care not to contaminate
adjacent or below floor electrical equipment. Should carpet become
contaminated, this should be replaced and adjacent structure checked for
evidence of contamination/corrosion.
4. Dry the affected area thoroughly, using a clean rag.
5. Replace any contaminated control cables.
6. If it is suspected that electrolyte has contaminated the structure, perhaps
by capillary action, the following action should be taken.
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(a) For lead/acid electrolyte (dilute sulphuric acid) apply sodium
bicarbonate powder to the affected area and wash down with a
saturated solution of sodium bicarbonate.
(b) For Ni-Cad electrolyte (potassium hydroxide solution) rinse the
affected area with 5% solution of acetic acid. If not available,
ordinary household white vinegar may be used neat.
In either case, finally rinse area with clean cold water, taking the same
precautions as in Item 2. Dry the area thoroughly.
If there is any doubt that this procedure has not been effective,
consideration should be given to removal of units and de-riveting the
structure for separate cleaning and inspection.
As sodium bicarbonate (alkali) is in itself mildly corrosive to light alloys,
testing the effectiveness of the cleansing operation may be carried out
using a piece of pH Universal Test Paper. Colour changes indicate the level
of acidity (red) or alkalinity (blue).
Alternatively, litmus paper may be used, satisfactory cleansing being
indicated by no colour change of either blue to red (acid) or red to blue
(alkaline).
NOTE. Acetic acid (5% solution) is not too detrimental to aircraft
structure/light alloys.
7. If any corrosion has occurred to the structure, carry out corrosion removal
procedures (refer to the AMM and to EASA module 7 book entitled
Corrosion in this series) and re-protect structure.
8. Fit and connect the battery (if removed) and test the system as per the
AMM.
9. Record (and sign) all the work done in the appropriate work
cards/Logbook. In all cases of electrolyte spillage, an ADD should be
raised detailing the area affected, the level of cleansing effected
(units/cables removed, etc) and calling for the area to be re-inspected after
24 hours and 14 days for signs of corrosive attack.
Should corrosion then be evident, appropriate action must be taken and
consideration given to repeat inspection at a later date.
CAUTION: In the event of the skin becoming contaminated with electrolyte, wash the
affected area immediately with plenty of clean cold water.
Should eyes become contaminated, flush immediately with plenty of clean cold water
or a propriety brand of eye cleaner such as Steriflex.
In either event seek immediate medical treatment.
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MERCURY SPILLAGE
Refer to Chapter 5 of the AMM.
Mercury is found in manometers and in some instruments. It may also be carried as
cargo on transport aircraft. If spilt on metals it can cause rapid corrosion and
embrittlement. The mercury will ‘run’ on the surface like small ball bearings and
quickly run into crevices, and joints.
The rate of corrosion can be so quick as to be apparent in just a few minutes and is
more serious than battery acid corrosion. It is, therefore, important that it is detect,
removed, and treated quickly. You should, of course, follow the procedures laid down
in the AMM/SRM for the aircraft but the following information is generally applicable.
Safety Precautions
1. Wear protective clothing, particularly gloves.
2. Do not swallow mercury or inhale the fumes, report to the medical
centre immediately if this happens.
3. Work in a well ventilated area.
4. Discard all contaminated clothing and materials. Dispose of in
accordance with the local authority regulations.
5. Wash hands, tools, and other equipment contaminated with mercury.
6. Do not smoke, eat or drink, while working with mercury.
Detection Methods
1. Visually. When spilt, mercury will form into ball-bearing like globules.
These will ‘roll’ along surfaces, into crevices, and into joints.
2. X-rays. If unsure of the exact location of mercury it can be seen clearly
on X-rays.
3. ‘Sniffer Gun’. A sniffer gun will pick up mercury vapours and give an
aural and visual warning.
Recognition of Corrosion Products
Mercury corrosion is impossible to rectify in-situ. The only suitable rectification of
corroded areas is by repair (patch or insertion) or by replacement.
Aluminium and Aluminium Alloys. Shows as a greyish powder or whiskery growth.
This growth often occurring within minutes of initial contamination.
Silver, Cadmium and Zinc. Shows as a slightly brighter area where the corrosion has
occurred. The area might be difficult to see.
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Fig. 26 LOCALLY MADE-UP MERCURY TRAP
Tackling Mercury Spillage
1. Take action immediately. Corrosion rates can be very quick so the
sooner action is taken the better.
2. Do not move aircraft as the movement can cause the globules to ‘run’
into other parts of the structure.
3. Isolate the area. Place rag or paper towels around the spillage area to
keep globules within the original area. Prevent people walking through
area (if on aircraft floor) to prevent spread of mercury on footwear.
4. Remove source of contamination (broken instrument etc.) - carefully.
5. Remove globules by:
(a) Suction. Use a standard vacuum cleaner with a locally made up
‘liquid’ type trap in the suction line before the vacuum cleaner. (A
glass jar with a screw top lid and two pipes entering through
holes in the lid will do. Figure 26).
(b) A special pick-up brush. This is drawn lightly over the mercury
which will ‘pick up’ on the bristles. Shake the brush carefully into
a glass container.
(c) Foam pad. Pressing the pad into the mercury and releasing it will
cause it to suck up the mercury. Squeeze into a glass container
to remove the mercury from the pad.
(d) Adhesive tape. This will pick up the smaller globules.
(e) Chemical application. Mix up a thin solution of calcium
polysulphide. Mixing this with the mercury will convert the
mercury into an inert mercuric sulphide. Allow the mixture to dry
for 2 hours then vacuum up with a normal vacuum cleaner.
6. X-ray the area to check that all mercury has been removed.
7. Remove panels, de-rivet structure as necessary. Any contaminated drills
should be disposed off as contaminated products.
8. Apply a thin film of oil to area provided corrosion has not started. This
will help prevent the onset of corrosion but cannot be guaranteed to
stop it.
- 48 -
9. Where mercury attack has started on structure it will have to be
removed and a patch/insertion repair carried out. Use the SRM for the
aircraft, and it is important that all the affected area is removed - with
an extra allowance for safety. If the corroded area exceeds the repair
limits the panel must be replaced. Corroded components should be
changed, appropriately labelled and returned to the manufacturers.
10. Record and sign for the work in the log book.
11. Call up for a further inspection to be carried out in the Tech log – say, 3
to 4 days later.
Note. When disposing of mercury and mercury products it is important to
follow local regulations. The mercury should be kept in clearly marked
glass or ceramic containers - sealed and annotated as contaminated.
Contaminated clothing should be stored (dry) in plastic bags and labelled.
The mercury and contaminated material should end up at a special site
suitably equipped to be able to handle these products. Contact your local
authority/local waste contractor (a fee is likely).
GROUND SERVICE CONNECTIONS
Ground service connections include all those connections that are made to the
aircraft to provide power or some other form of supply/return service. These
connections could include:
* Refuelling/defuelling.
* Potable water (drinking water).
* Toilet system drains.
* Pitot/static systems.
* Pneumatic supply.
* Hydraulics – fill system provision and pressure supply and return
connections.
* Electrical connections.
Most of these are dealt with in the appropriate LBP book on the subject. Here we will
deal with just three – electrical, hydraulic and pneumatic ground supplies.
Pneumatic Ground Supplies
On some aircraft this would be taken as the supply of compressed gas for the
charging of gas bottles, oleos etc. On other aircraft the term ‘pneumatics’ would mean
the supply air for cabin air conditioning/pressurisation – usually from the
compressor side of the jet engine to the air conditioning packs/de-icing systems.
When dealing with compressed gas from pressurised transportation gas bottles
always check the following:
1. Check transportation bottles are within test date.
2. Ensure that the correct gas is used – air – nitrogen etc (check AMM).
3. Ensure system is serviceable to charge.
4. Charge slowly.
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5. When using an adapter gauge always ensure that the pressure readings
from the various gauges – charging bottles, adapter, aircraft – all read
the correct reading. Stop the charging if readings do no correlate, and
investigate the reasons why.
6. Ensure that adapter gauge is within test date.
7. Allow pressure to stabilise after charging.
8. Check any pressure/temperature graphs.
9. Fit all blanks.
Air supplies for aircraft pneumatic systems can come from the engines, APU or
(whilst on the ground) from an engine driven ground supply trolley/cart. The duct
connection must be clean and the system must be checked that it is not pressurised
before connection is made. The system must also be checked that it is serviceable
before air supply commences.
The air supply cart should have a certificate of serviceability both in relation to it’s
motive power, exhaust emissions, and quality and rate of air supply.
When operating the unit ensure:
* A fire extinguisher is available.
* It is placed as far away from the aircraft as possible consistent with the
ability to connect the supply hose.
* Its air supply rate is within the parameters laid down in the AMM
(pressure and supply rate).
* When disconnecting ensure that the pressure is released.
* The aircraft is configured to accept the supply and the pneumatic
system is serviceable.
Electrical Ground Supplies
For dc supplies a set of batteries mounted on a trolley or an engine driven dc
generator may be used. The master switch on the trolley is off before connection is
made. The aircraft services switches are either off or their position corresponds with
the service selection – ie flaps up, selector switch up.
The AMM is consulted before power is applied.
The power supply plug (and the aircraft socket) may vary in design. A typical dc
supply plug is shown in figure 27. The plug consists of three pins, handed so it
cannot be fitted to the aircraft the wrong way round. The centre large pin is the main
supply pin, the other large pin is an earth/ground pin. The small pin is a relay
control pin. When plugged in and the master switch on, it supplies a small current to
operate a relay on the aircraft which switches out the aircraft battery supply and
switches in the external supply (centre pin) to the dc bus bars. It also causes a
cockpit indicator to show that external power is on.
When the external master switch is switched off the relay resets, external power is
switched off and internal power (batteries) are switched onto the bus bars.
For ac supplies an engine driven ground cart is used. The power supply socket
usually contains 6 pins, handed, so fitment to the aircraft can only be made in the
correct orientation.
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Fig. 27 EXTERNAL DC POWER SUPPLY PLUG
Three large pins are for the supply of the 3 phases, with the forth large pin being a
ground/earth connection. The two small pins are dc control pins which operate
relays on the aircraft to switch in/out the external power supply.
Figure 28 shows the external power panel of the B777. There are two power supply
connections – the primary and the secondary. The primary is to be used first with the
secondary being connected if more power is required. On many aircraft there is only
one external power connection.
Fig. 28 EXTERNAL ELECTRICAL POWER SUPPLY PANEL – B777
The panel shows the connection status of the supplies together with support
strapping for the (heavy) power supply cable.
In general, power supply panels may have the following equipment/indications:
* 3 external ac power circuit breakers.
* dc control circuit breakers.
* Power connected/power ON lights.
* Panel illumination lights, interphone socket and pilot’s call button.
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Figure 29 shows the indications on the flightdeck for power supply status. It is the
B777 electrical panel and is a good example of a large aircraft electrical supply
indicator. Note the status indications of the primary, secondary and APU supplies.
To connect power:
* Check the AMM.
* Ensure all systems are serviceable.
* Ensure all switches are off or set to the position of the service to which
they relate (to prevent any service from moving when power is switched
on).
* Check that supply cart engine is running correctly and voltage and
frequencies are correct. The same safety precautions apply here as for
any internal combustion engine powered equipment running in the
vicinity of aircraft.
* Insert ground power plug and support using restraining straps.
* Turn power on at the supply.
* Check ‘power available’ lights come on, on the aircraft panel. If they do
not then supply voltage or frequency may be a problem.
* If ‘power available’ lights are on, press ground service power switch on
panel to apply power to the aircraft ground service bus bar. Note
indications.
* Press the primary power switch to apply power to the aircraft power
supply bus bars. Note indications.
Fig. 29 ELECTRICAL POWER INDICATION
Hydraulic Ground Supplies
This could include refill connections, system selector valves etc, but we will
concentrate on the supply of external hydraulic power.
The hydraulic system may require the use of more that one external power test
rig/cart – check the AMM.
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The test rig/cart is usually powered by an internal combustion engine and should
meet the safety requirements applicable to all these type of engines when operating in
the vicinity of aircraft.
The test rig must be fitted with the same type of pump that is fitted to the aircraft -
constant volume (2 connections, pressure and return) or constant pressure (three
connections, pressure, return and idle lines) - or as specified in the AMM. The rig
must be run at the rpm as specified on the rig instruction panel to meet the pressure
and volume flow rate requirements as required by the aircraft system/s.
Fig. 30 HYDRAULIC EXTERNAL POWER PANEL OF THE AIRBUS AIRCRAFT
The test rig should be checked to see if it contains the correct hydraulic fluid –
normally marked on a plate fixed to the rig – if it doesn’t, get a rig that does. It is
connected to the aircraft using hoses with self-seal quick release connections. They
are sized so that the hoses cannot be cross-connected:
* For 2 hose connections (constant volume pump). Large = suction line.
Small = pressure line.
* For 3 hose connections (constant pressure pump). Large = suction line.
Medium = pressure line. Small = idling line.
Check the following when connecting/disconnecting hydraulic power:
1. Check the AMM.
2. Carry out the normal safety precautions in relation to the running of an
internal combustion engine in the vicinity of aircraft.
3. Check that the hydraulic system and all associated systems are
serviceable and ready to be tested (fluid levels, accumulator gas
pressures, completeness etc).
4. If the landing gear is to be tested the aircraft should be on jacks and
suitably trestled/shored.
5. Check flight deck selectors correspond with actual position of systems.
6. Have electrical power on.
7. Connect hydraulic hoses.
8. Start hydraulic test rig – adjust to correct rpm – allow to warm-up.
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9. Operate clutch to engage pump – note that no services move. If they do,
either dis-engage the pump or note they are supposed to move and are
prepared for it (check AMM).
10. Check pressure gauges, low pressure warning lamps etc in the flight
deck.
11. After all testing is completed and the landing gear is locked down with
‘3
greens’ showing the clutch can be dis-engaged and the rig shut down.
12. Using a ‘C’ spanner or special tool to undo the self-seal couplings.
13. No fluid should leak, but if it does then ensure the self seal coupling
seals correctly and the leak stops, fit the blank and check the level of
the reservoir.
””””””
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APPENDIX – ESSAY QUESTIONS
This appendix has been added to provide the reader with some idea as to the essay
questions being asked by the CAA, and the answers. This has been thought
necessary because the areas being asked questions on are actually in other modules
(principally jet engines module 15 and airframes module 11). But because the way
the syllabus is written it has meant that the CAA can include them in module 7.
Module 7 syllabus states, amongst other things, “Types of defects and visual
inspection techniques” (BI and B2) and “Inspections following abnormal events such
as heavy landing and flight through turbulence” (B1).
The answers given here are our own and you must give your own in any CAA
answers. They are quick to pick up what are called ‘model answers’ and
memorised/copied answers come into that group.
Our answers are an answer to the question but also include information about the
question – which helps you to learn. It is most important that when you answer any
CAA question that you answer that question and not one you think it is, or should be.
Note that some of the information in the answers might be better understood if the
appropriate book is read in the module 11 or 15.
Note also that we produce an EE programme specifically written to cover the essay
questions for modules 7, 9 and10. It provides a guide as to the technique of the essay
answer and gives the student questions to be attempted. When completed they are
returned to the appropriate LBP tutor for marking and comment. The programme
also contains a list of the sort of questions asked and indications as to the answers.
The questions in this book are additional to those in our EE programme with question 1 being almost certainly for the B1 person only.
1. QUESTION. The pilot reports a smell from the flight deck air conditioning system.
Detail the possible causes and state your action to clear the aircraft for flight.
Confirm if it is a burning smell. Confirm if it is an electrical smell, an oil smell, a
hydraulic smell or a debris smell and that its actually coming from the air
conditioning ducts.
Check for any shorting of electrical parts in any part of the air conditioning system –
any part of the system up to the mixing chamber where the cold air (after the air
cycle turbine) meets the hot air from the engine/engine compressor, and carry out
any BITE checks.
Change any overheated wiring/electrical components as per the AMM.
If an engine oil smell, and air tapped from the engine carry out investigation as to
engine/s oil consumption over past few flights and any reports of engine/s over-
heating. Carry out a visual check of engine oil seals. Change engine if found
defective. If hydraulic smell check the hydraulic reservoir pressurisation system (non-
return valves in particular) and rectify as necessary.
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If air delivered from engine driven compressor check compressor oil seals and
compressor for over-heating. Change compressor if found defective. Check engine
overheat detectors/air duct temperature detectors (recorded on aircraft fault
computer if fitted) and take appropriate action.
For heating systems that use heat exchangers using engine exhaust pipes as the heat
source and combustion heaters check heat exchangers for leaks and change if
defective. Check CO2 detectors in cabin for correct operation.
Examine combustion heaters for serviceability and correct operation and leakage.
Change if not functioning correctly.
If smell is a debris type smell check ducts for cleanliness, change all air filters,
change coalescer in water separator and check all lagging for dampness and smell.
Check cold air unit for oil leaks. Change if found.
Record all work done and certify and issue CRS.
2. QUESTION. Describe how you would check for water contamination in fuel and
what other checks would you carry out at the same time. Checking for fuel contamination in not actually in the module 7 syllabus, though refuelling/de-fuelling is. The CAA have asked essay questions based on fuel sampling on both B1 and B2 examinations.
To check for water contamination proceed as follows:
1. Allow the aircraft to stand for a few hours after refuelling.
2. Ensure the aircraft is in the attitude as laid down in the AMM -
usually laterally level and longitudinally as specified.
3. Using a clean glass container (clean using alcohol isopropyl) drain
each aircraft tank in turn from its drain valve until no more water
comes out with the fuel. Use the drain valves provided and/or a purging
tool (AMM).
If unsure if water is present use a colour indicator (eg a soluble food
colouring) is added to the container which will show up the water as a
colour. Alternatively a water detector kit may be used, eg the Shell
Water Detector kit. Also a hydrometer may be used to check the specific
gravity.
Any water present may show up as suspended droplets which will make
the fuel show up as cloudy when looked at using a back-light. Free
water will show up as larger droplets or a layer of water at the bottom of
the glass. If water is found continue to drain until all water is removed.
4. If the amount drained is within normal limits as per the AMM discard
the drained liquid as laid down in the local airfield regulations.
5. Close and lock drain valve. Secure panel and record details in the
aircraft log book.
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6. If excessive water is present carry out the following:
* Refer to the AMM and/or the aircraft manufacturer for any
specific instructions.
* Wait a further period of time and drain each tank again.
Take note if significantly more water came from one tank
more than the others. This might mean local rain water
ingress or tank water ejector failure.
* Get the fuel supplier to check the fuel supplied either in
the tanker (bowser) of from the bulk underground supply
system. Get a report from the supplier. (Tankers/fuel
supplies should be water drained at least daily). If it is a
bulk fuel supply problem then this must be rectified by the
supplier.
* Check for obvious signs where water (rain water) could get
into the aircraft tank (rare). Rectify as necessary.
* Check that the automatic sumping pump (water
ejector/ejector pump) is working. If not change.
* Check the Tech Log to see if pilot reports include any
engine problems.
* If fuel is seriously contaminated (which is rare) then the
tanks must be drained and refilled with ‘good’ fuel, the
airframe system re-primed, the engine/s system/s re-
primed and an engine run carried out.
Remember that the fuel will be drained back into the
bowser so the bulk fuel supplier must be informed why the
aircraft tanks are being drained.
If the contamination is the bulk fuel supplier’s fault then
there will be some financial adjustment to the aircraft
operator’s fuel account.
* All work carried out on the aircraft must be recorded and
signed for in the airframe and engine log books.
* Consult the bulk fuel supplier re the disposal/treatment
of the drained fuel.
7. If bacteria contamination suspected carry out a microbe/fungus
detection check as follows:
* From the tank drain, drain a small quantity of fuel into a
clean container.
* Use a commercially available tester kit as per the AMM.
* Put a fuel sample in each of two clean glass containers (1
and 2). One container (say container 2) will have a
quantity of biocide added from the tester kit. +
* Cover and allow the two containers to stand for 48 hours.
If there is a colour change in container 2 then there is fuel
contamination.
* Check all remaining tanks. Any that show contamination
must be drained and inspected internally for
discolouration (brown or black), corrosion or any
deterioration. Any damage must be repaired as per the
AMM/SRM or the tank replaced.
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* Check fuel system components (including filters) for
internal damage and debris blockage. Clean/replace as
necessary.
* Carry out an engine run if any components have been
replaced.
* Carry out any duplicate inspections as necessary.
* Record all work done in the aircraft/engine log book/s and
sign.
+ Some kits use detection papers.
While carrying out a water sampling test it would be obvious to also check for
other contaminants besides bacteria. If debris is found such as particles of metal,
rubber, etc then further checks are to be made, eg:
1. Check the AMM/engine manufacturers manual.
2. Check the fuel filters.
3. Check the oil filters and any magnetic plugs.
4. Depending on what is found in the filters determine if any
component (fuel tank, bearing, pump etc) is breaking up.
5. Carry out a particulate laboratory test such as a SOAP
(Spectrometric Oil Analysis Programme) test to determine
what the particles are and what component/s they came
from (up to 11 elements can be detected by these tests).
6. Change the offending component/s.
7. Depending on the size, the amount and the source of the
debris the engine/s may have to be changed and returned
for overhaul. The system may also have to be flushed out
depending on where the particles originated from –
pumping clean fuel from the fuel tanks to an open fuel
pipe at the engine.
8. If not too severe carry out an engine run and carry special
checks for fuel/oil contamination over the next few flights.
The above answer is long and the author would not expect that this amount of information can be written down in the time allowed in the examination, but it is comprehensive and provides the reader with a sound background as to how fuel contamination can be examined for.
””””””
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