jig inspectors workshop - · pdf file–petronas . jig technical forum ... standard that...

JIG Inspectors Workshop

Teddington

September 28th

2012

Joint Inspection Group Limited JIG JV Managers Workshop – Teddington 2012

JIG Standards and the Checklist

Ger O’Donnell

Global Operations Standards & Compliance Manager

Shell Aviation

&

Neil Frances

Global Operations Standards Manager

Air BP

JIG Technical Forum

• Committee members :

Ger O’Donnell – Shell Chairman

Dave Pullinger - ExxonMobil

Neil Frances - BP

Sylvain Duperrier - Total

Terje Pedersen - Statoil

Nic Mason / Bill Simpson - Q8

Nan YanBo - Chevron

Francesco Pristera - ENI

Tony Rowe - JIG

Trevor Bertrand - British Airways for IATA

TBA – for IATA

Martin Hunnybun – Energy Institute

:

– AFS

– APSCO - PTT

– ConocoPhillips - Puma Energy

– CNAF - SAFCO

– ASIG - Skytanking

– CEPMA - Swissport

– CLH Aviacion -Thy Opet

– DLA - Valero

– EKO - Vopak

– ENOC

– OFC

– Petronas

JIG Technical Forum

And a special acknowledgement for all of the efforts of Anthony Kitson-Smith

formerly of ExxonMobil Aviation who was the Technical Forum Chairman for the

duration of the reviews and revisions leading to the publication of Issue 11.

JIG 10 to 11 – Biggest JIG revision to date

JIG Guidelines moved to Standards

Numerous changes in HSSE, PControl, Shalls, Defuelling, Appendices, etc.

New JIG Checklist

JIG 12 already underway

WORK TOPICS FOR 2012

1. Initiate work on Issue 12 to start to pick up strands from Q4 2011

2. Produce JIG 11 checklist for JIG 1,2,3,4

3. Issue technical bulletins as required e.g.

1. EI 1583 Monitors (done)

2. Introduction to JIG 11 (done)

3. Filtration – similarity and differential pressure (done)

4. High level alarms (in progress)

5. Addendum to JIG 11 (done)

6. AFQRJOS Checklist 26 (issued) and Checklist 27 (In progress)

4. Timeline for roll-out of JIG 11.

1. New checklist by end August

2. Inspector training April & September as new checklist will be used from 1st January 2013

3. JV Managers training September 2012

4. Compliance required by end December 2012

Key Updates - General

• Wording harmonization achieved for JIG 1, 2, 3 issue 11 (Published Jan 2012) and JIG 4 issue 2. (Expected October 2012)

JIG 1, 2, 3 section 1.4 & JIG 4, section 1.1 new wording added –

“Where applicable national or regional legislation requires compliance with a standard that differs to the Standard, this shall be clearly documented. However, the use of Variance Approval Certificates is not required.”

• Mandatory requirements in this standard are designated by the word “shall.”

Recommendations and best practices are designated by the word “should.”

Optional items are designated by the word “may.”

• Note: Only the latest revision of any document or standard, referenced in this

document, shall be considered. A glossary of terms, table of acronyms and a

list of useful publications is included at the beginning of this standard.


7

Summary of frequencies JIG 1

TEST FREQUENCY

Fuelling vehicles Daily Weekly Monthly 3-monthly 6-monthly Other Reference

Interlock override seals x 4.4

Interlock function x x 4.4

Bonding wires x x 4.5

Deadman override seals x 4.7.4

Deadman performance x Yearly 4.7.2

Pressure/surge control test x 4.7.1

Aviation hoses x x x A13

Aviation hose flush 2x

hose contents

Overwing fuelling hose

Underwing fuelling hose

X

x

4.8.3

Hose-end strainers x 4.16

Bulk meters x 4.9.1

Master meters 3 years 4.9.1

Critical pressure gauges x 4.10.1

Master pressure gauges 3 years 4.10.2

Piston differential press

gauges

x 4.10.3

Elevating platform

lowering

x 4.11

Elevating platform wand

sensors

x 4.11


8

Summary of frequencies JIG 1

TEST FREQUENCY Fuelling vehicles Daily Weekly Monthly 3-monthly 6-monthly Other Reference

Hydrant pit coupler wear check Yearly 4.12

Fueller tank low point draining x 5.2.1

Fueller tank/vents/manlids

inspection x

for top loaded

fuellers

Yearly 4.14

Fueller roof area water drains x 4.14

Fueller tank cleaning 5 years 4.14

Fuellers routinely used for

defuelling Assay test x 5.9

Product recovery tanks x 4.15

Electrical Equipment yearly 4.16

Fueller high level cut-off

devices x Yearly

high/ high wet

test

4.17

Hydrometers & thermometers

Resistance Temperature

Devices

x

x 4.19

Fire extinguishers x x Yearly 4.20

Conductivity meters 3 years 4.22

Lanyards on reel (isolation

check) x 3.3.2

Water slug valves on filters x A6.2.6


9

Summary of frequencies JIG 2 TEST FREQUENCY Airport Depots Daily Weekly Monthly 3-monthly 6-monthly Other Reference

Storage tank low point draining x 6.1.1

Floating suction arm check x 6.1.2

Tank vents and mesh screens x 6.1.3

Tank high level alarms x Yearly 6.1.4

Conductivity (if no fuel received) x 6.1.5

Periodic test (static stock) x 6.1.7

Double block & bleed valve drains x 6.1.8

Tank external visual inspection 1/2 years 6.2.1

Tank internal inspection and cleaning Cause or

3/5 years

6.2.1

Hydrant low point flushing x x 8.1.1

Flush unused hydrant pits/spurs x 8.1.3

Hydrant pit condition/cleaning x A14.1.1

Hydrant pit valve integrity check x A14.1.2

Hydrant pit valve dynamic test Yearly A14.2

Hydrant pit valve wear check Yearly A14.2

Hydrant emergency shut down x 8.4

Hydrant integrity (leak detection) x 8.7.1

Hydrant/buried line pressure test Yearly 8.7.2

Hydrant valve chamber check x Yearly 8.10

Hydrant low point servicing vehicle tank

sump flushing

x 2.3.4 (j)


10

Summary of frequencies JIG 1&2

TEST FREQUENCY Airport Depots Daily Weekly Monthly 3-monthly 6-monthly Other Reference

Bonding wires x x 10.1

Bulk meters x 10.3.1

Master meters 3 years 10.3.1

Critical pressure gauges x 10.4.1

Master pressure gauges 3 years 10.4.2

Piston DP gauges x 10.4.3

Aviation pressure hoses x x x A13

Gauze strainers x A6.5

Hydrometers & thermometers Resistance Temperature Devices (RTDs)

x x 10.6.4

10.6.1

Conductivity Meter 3 years 10.12

Torque wrench 5 years 10.12

Fire extinguishers x Yearly 10.7

Stock control x 10.11

Filter draining x A6.2.1

Filter Dp graphs x A6.2.2

Filter colorimetric test x A6.2.3

Filter internal inspection Yearly A6.2.4

Micro filters 3 years A6.3.1

Coalescer element change 3 years A6.3.2

Monitor element change As per

manufacturer A6.3.4

Key updates – Sampling Diagram Improved

Key Updates – Filters

Status:

• JIG requirement to determine ‘maximum operational (maximum achievable) flow rate’ on filter vessels, also recommend to use this value for differential pressure (dp) correction as opposed to ‘maximum rated flow’ of the vessel. Maximum Operational Flow to be marked on the vessel.

• EI 1583 6th Edition Filter Monitors – requirement to implement 2 inch by end 2012 – advantages - media migration quantitative evaluation, salt resistance, end cap component adhesion. JIG Bulletin 49 (Jan 2012) mandates use of 6th edition by end 2012.

• At IATA, it was agreed to go with EI wording proposal of maximum achievable flow and vessels should be de-rated where necessary and elements removed and blanks fitted in the correct order / position.

Key Updates – Hydrants

Hydrant Leak Detection systems

• Last Update: Survey of Tightness Control Systems’ operation in Europe, new EI standard and guidance material for leak-testing and monthly monitoring and annual cathodic protection system check was proposed.

• Status: EI to develop standard (EI 1560) and guidance material for leak detection and pressure testing of hydrant systems. New JIG 2 wording.

• ”and cathodically protected where appropriate. Cathodic protection should be installed for all new hydrant systems.”

• “EI 1540 Cathodic protection should be installed for all new hydrant systems.”

• “Where fitted, an agreed maintenance programme shall be in place. Monthly monitoring by competent persons and an annual full system check by a trained & competent person is required.”

Key Updates – Hydrants

Vehicle Air Supply

Normal Configuration (Fuelling and Flushing from Hydrant Pit Valve)

Deadman

Pressure Regulator

Timer Switch

ILPCV

Air

vent

Hydrant Pit Valve

Test Valve

Vehicle Air Supply

TEST Configuration for testing Dual Pilot Valve Closing Time

Deadman

Pressure Regulator

Timer Switch

ILPCV

Air vent

Hydrant Pit Valve

Test Valve

Arrangement for testing Hydrant Pit Valve Closing time on Hydrant Pit Valves fitted with Dual Pilot Valves.

Key Updates – Hydrant Pump Protection

• Suggested Hydrant pump process, safety features, and their maintenance:

• Hydrant pump process management should be controlled by a Programmable Logical Controller

• Back pressure control valves on recirculation lines shall be maintained periodically according to manufacturer specifications

• Maintenance operations shall be done by competent personnel trained by the manufacturer or their approved representative to perform the required tasks.

• On the basis of Risk Assessment, other instrumentation should be installed such as infrared heat and fire detection, bearing vibration monitoring, bearing temperature monitoring, product temperature monitoring.

• Suitable provision of fire-fighting equipment shall be determined by a risk assessment.

Key Updates - Tanks

Maximum intervals (years)

Visual inspection from

outside

Internal inspection and

cleaninga

JET FUEL

Normal frequency 1 Causeb or 3

When conditions stipulated

are met c

2 Causeb or 5

AVGAS

Normal frequency Not required Causeb or 3

When conditions stipulated are

met c

Not required Causeb or 5

“Cause” for aviation fuel tanks is defined as:

• Tank internal surfaces are dirty, i.e. the inspection reveals microbial growth or build up of sediment exceeding

approximately 20% of the tank bottom surface

• Presence of microbiological contamination, excessive dirt, rust or other debris in water drain samples

• Fuel quality downstream indicates the presence of excessive contamination, e.g. short filter life, poor Millipore

results or high particle counts (e.g. 18/16/14 which approximates to 1mg/litre of an average dirt containing rust

and sand.)

• The condition of the water drain samples shows the presence of excessive rust or microbiological growth or

surfactant contamination.

• “Cause” shall require more frequent tank cleaning than the maximum limits shown.

• C – Necessary conditions. Agreement of Participants, Historical record of cleanliness, effective inspection without

entry and fully epoxy lined .

Key Updates – Tanks

New Text for JIG 2/3

6.22

No chemicals, or cleaning materials that could adversely affect the aviation fuel to be stored in the tanks, shall be used unless required for decontamination of the tank. A Variance Approval Certificate shall be required. If it was found necessary to use a cleaning chemical or if repairs were carried out, or if required by one of the participants, a Composite Sample shall be taken for a Periodic Test before product release.

Key Updates - PRTs

New Text for JIG 2 and JIG 3

6.2.5 – “Product Recovery Tanks (Not applicable to tank-side fast

flush tanks). Tanks shall be inspected without entry quarterly for

cleanliness and condition. Cleaning and repairs to the internal

lining shall be carried out as necessary. An industry endorsed

microbial growth test on a sump sample after flushing, may be

carried out as an alternative to quarterly inspections.

.

Key Updates – Underwing Fuelling

Hydrant systems: Underwing fuelling

Status:

• Two hydrant fuelling connection procedures allowed now but a single

sequence of disconnection required.

• Risk assessment criteria are included

• IATA would prefer one agreed sequence for all into-plane operators at each

location, but this is not within the control of JIG.


Appendix A9 (JIG 1) Recommended Hydrant Connection Sequences Hydrant Dispenser Fuelling Connection / Disconnection Sequences (See 6.5.2)

Sequence 1 Sequence 2

Connection - Pit to Aircraft Connection – Aircraft to Pit

Bond to Aircraft Bond to Aircraft

Attach lanyard and pull to ensure pit valve is closed Connect delivery hose(s) to aircraft

Extend lanyard and remove dirt/moisture from pit

valve adapter and hydrant coupler

Attach lanyard and pull to ensure pit valve is closed

Connect hydrant pit coupler and airline to pit valve

and position pit marker

Extend lanyard and remove dirt/moisture from pit

valve adapter and hydrant coupler

Open hydrant pit coupler Connect hydrant pit coupler and airline to pit valve

and position pit marker

Connect delivery hose(s) to aircraft Open hydrant pit coupler

Get confirmation of fuel figure to start fuelling from

A/C engineer / pilot

Get confirmation of fuel figure to start fuelling from

A/C engineer / pilot

Open pit valve (if manually operated) Open pit valve (if manually operated)

Open meter delivery valve and activate deadman

control to start delivery

Open meter delivery valve and activate deadman

control to start delivery

Check hydrant pit coupler for leakage Check hydrant pit coupler for leakage

Note: If the sequence of connection and disconnection is broken due to distraction the operator shall begin the sequence again.


Appendix A9 (JIG 1) Recommended Hydrant Disconnection Sequences Hydrant Dispenser Fuelling Connection / Disconnection Sequences (See 6.5.2)

Disconnection – Aircraft to pit

Release deadman and close meter delivery valve

Pull lanyard to close pit valve

Disconnect delivery hose(s) from aircraft

Replace the aircraft fuelling adapter cap (if fitted) and close the fuelling

panel.

Close hydrant pit coupler

Disconnect hydrant coupler, airline, lanyard and pit marker; and stow

Remove bonding cable

Complete delivery documentation

COMPLETE THE 3600 WALKAROUND CHECK - REMEMBER TO LOOK UP TO AIRCRAFT

COUPLINGS

Note: If the sequence of connection and disconnection is broken due to distraction the operator shall begin the sequence again.

Key Updates – Defuelling

Aircraft Defuelling

• No longer any differentiation between a Load Adjustment or a Maintenance defuel – all defuels to be treated the same.

• Defuelled product to be returned to an aircraft of the same airline or to an aircraft of another airline with their written permission.

• Any additional requirement shall be negotiated as a separate contract between airline and into-plane fuel provider.

Key Updates – Pressure Control

Testing of fuelling vehicle pressure control systems simplified.

Routine verification of venturi sense pressures no longer required.

Surge testing of in-line pressure control valves no longer required.

Key Updates – Hoses

Pump output pressure 6 monthly

hydrostatic

test/

pressure.

Commissioning

new hoses with

factory fitted

couplings

Attaching/ reattaching

couplings

Less than or equal to

5.5 bar (80psi) No

requirement 15 bar 20 bar

Greater than 5.5 bar

(80psi) 15 bar test 15 bar 20 bar

Simplified Table of Required Hose test pressures

Damaged hoses

Any of the following abnormalities noticed during daily operations or monthly

or 6 monthly tests requires immediate hose replacement even if the hose was

to pass a hydrostatic pressure test:

• soft spots, kinks/ deformities, bulges or blisters, excessive abrasion or

cracking exposing the carcass textile reinforcement,

• any cut in the hose structure which has damaged the carcass textile fabric,

• if the hose has been run over once by any vehicle.

• No need to remove some hose fittings for testing.

Key Updates – Hoses

Improved Hose End Nozzle Screen Inspection Rig Diagram

Key Updates – Deadman & Reversing

Cordless Deadman Range

• Last update:

• Maximum range of 10m maybe insufficient, so 20m was proposed.

• Status:

• Issue 11, JIG 1, section 3.1.13, JIG 2, section 7.2.1 – “Cordless

deadman controls may be used provided that they are securely preset to

shut down if the distance between the hand-held control and the fuelling

vehicle exceeds approximately 20 metres. This shall be evaluated on an

annual basis.

Reversing of fuelling equipment and clear exit from stands

• Status: Use of stand plans agreed on a minimal initial basis, reversing only

with a competent guide man (except minor repositioning of hydrant

dispensers) and controlled speed.

Key updates – Stand Plans

Stand plans, drawn to scale, should be developed with the airport authority for every

aircraft parking position. These stand plans provide guidance for the fuelling operator

in the safest approach and exit route to/from the aircraft fuelling position. Similar

parking positions may be consolidated into a single plan. These shall show as a

minimum:

• stand number and location

• aircraft types (include all aircraft likely to use the stand)

• location of hydrant pits and hydrant emergency stop buttons (if applicable)

• fuelling vehicle access/exit routes (shown by colour-coded arrows)

• fuelling vehicle parking position during fuelling

• fuelling vehicle standby position while waiting to fuel

• Stand plans should be prepared in a suitable format for retention in fuelling

vehicle cabs.

6.2.2 Stand Plans


28

Key updates – Stand Plans

Example of a Stand Plan


29

Key Updates – Additions

• “Should” and “Shall” Definition (removal / replacement of

terms “must” and “it is recommended”.

• Glossary of terms

• List of Acronyms

Session Two – JIG 11 Inspection Checklist

• Draft checklist circulated to Inspectors in Mid April 2012.

• Checklist sub-group of JIG inspectors formed and worked on new checklist from April – August.

• Updated Checklist now agreed by Operations Committee

• Being introduced into the JIG Inspection Tracking System for a short trial period and a “go live” date of 1st January 2013.

Key Changes:

• All JIG Inspections in 2013 will be performed using the new Checklist.

• Overall Assessment: 3 types-Good, Satisfactory or Less Than Satisfactory

• Option for nomination of an Excellent Certificate for sites ranked GOOD

• All Recommendations will have “Due Dates” for completion.

• Due Dates: At least 3 months from report date (max 6 wks after visit) unless considered risk demands earlier due date.

• Due Dates: Maximum date of 12 months from inspection. Most open RECs will therefore be Overdue in next inspection.


31

Key Updates – Inspection Checklist

GM Company focal points should be in touch about the rollout.

New checklist is effectively being launched here today

We will use the remainder of today’s session to run through the checklist.

Please raise any questions or comments

ADH & IP Checklist (Jan 1st 2013)

SD Checklist going through final comment phase. (Jan 1st 2013)

jig inspectors workshop - · pdf file–petronas . jig technical forum ... standard that...

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