jig standards session.ppt...torque wrench 5 years 10.12 fire extinguishers x yearly 10.7 stock...
TRANSCRIPT
JIG Workshop - JIG Standards
Orlando
March 12th -14th 2013
Presenters:
Ger O’Donnell
Global Operations Standards & Compliance Manager
Shell Aviation
&
Nic Mason
Technical Services Manager
Q8 Aviation
Agenda:
JIG Standards
Technical Forum Committee TF Drafting Working Group
JIG Technical Forum work topics for 2013
JIG Issue 11 – Changes
JIG Issue 12 & Process
JIG Standards
JIG Structure
TF Drafting WG
Misfuelling Prevention WG
TF Drafting WG
Website WG
Technical Forum Committee
� Ger O Donnell, (Chair) Shell Aviation
� Neil Frances, BP
� Sylvain Duperier, Total
� Terje Pedersen, Statoil
� Bill Simpson, Q8
� Nan Yanbo, Chevron
� Francesco Pristera, ENI
� Dave Pullinger, ExxonMobil
� Tony Rowe, JIG
All Associate Members including but not limited to:
� AFS , APSCO , ASIG, CEPMA, CLH Aviacion, ConocoPhillips, IATA (2 reps), EKO, ENOC, EI, Hansaconsult, OFC, Petronas, PTT,
SAFCO, Skytanking, Vitol Aviation, Vitol Terminal, Vopak & World Fuel Services, All Associate Member companies.
Technical Forum Drafting working Group
� Ger O Donnell, (Chair) Shell Aviation
� Neil Frances BP
� Sylvain Duperier, Total
� Terje Pedersen, Statoil
� Bill Simpson, Q8
Technical Forum Drafting working Group
� Nan Yanbo, Chevron
� Francesco Pristera, ENI
� Dave Pullinger, ExxonMobil Aviation
� Tony Rowe, JIG
Two Associate Members to be nominated in 2013:
JIG WORK TOPICS FOR 2013
1. Embed JIG Issue 11 & inspection checklist for JIG 1,2 & 3
2. Continue work on Issue 12 (commenced in Q4 2012)
3. Issue technical bulletins as required e.g.
1. Filtration dP Switches (done)
2. AFQRJOS Issue 27 (done)
3. High level alarms (in progress)
4. Safety Bulletins (as required, 1 in 2013 done)
5. Product Quality (as required)
6. Common Processes (as required, e.g. Stock Control)
4. Expected Timeline for completion and roll-out of JIG Issue 12.
1. TF DWG over 2013/2014
2. Sign-off in late 2014 by JIG Ops Com and Council. Launch Q1 2015
3. Inspector training 2015 for commencement of inspections to Issue 12
4. JV Managers training to Issue 12 in 2015
5. Compliance required by end December 2015
Key Updates - General
� Wording harmonization achieved for JIG 1, 2, 3 issue 11 (Published Jan 2012) and JIG 4 issue 2. (Published November 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 JIG Standards are now 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 the JIG
Standards, shall be considered. A glossary of terms, table of acronyms and a list of
useful publications is included at the beginning of the standard.
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
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 testx 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
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)
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 & thermometersResistance 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
manufacturerA6.3.4
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 was to implement 2 inch by end 2012 – advantages - media migration quantitative evaluation, salt resistance, end cap component adhesion. JIG Bulletin 49 (Jan 2012) mandated 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
Arrangement for testing Hydrant Pit Valve Closing time on Hydrant Pit Valves fitted with Dual Pilot Valves.
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
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
“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.
Key Updates – Underwing Fuelling
Appendix A9 (JIG 1) Recommended Hydrant Connection SequencesHydrant 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.
Key Updates – Underwing Fuelling
Appendix A9 (JIG 1) Recommended Hydrant Connection SequencesHydrant Dispenser Fuelling Connection / Disconnection Sequences (See 6.5.2)
Note: If the sequence of connection and disconnection is broken due to distraction the operator shall begin the sequence again.
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
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
Simplified Table of Required Hose test pressures
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
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
6.2.2 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.
Key updates – Stand Plans
Key Updates – Additions
“Should” and “Shall” Definition (removal / replacement of terms
“must” and “it is recommended”.
Glossary of terms
List of Acronyms
Key Updates – Inspection Checklist
� Draft checklist circulated to Inspectors in Mid April.
� Checklist sub-group of JIG inspectors formed and worked on new checklist from
April – August.
� Updated Checklist agreed by Operations Committee
� Went live in JITS on 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.
Key Updates – Inspection Checklist
� Draft checklist circulated to Inspectors in Mid April.
� 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 from Jan 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 should therefore be Overdue in next inspection.
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