Naval Aviation Maintenance Program for Fuel Surveillance
References:
1. OPNAV 4790-2G: Establishes the Fuel Surveillance Program
Requirements.
2. NAVAIR 01-1A-35(Aircraft Fuel Cells and Tanks): Provides
procedures for fuel sampling and states that only
trained and experienced personnel shall perform the fuel
sampling process.
3. NAVAIR 15-01-500(Aircraft Preservation Manual): Directs
when fuel samples are to be taken given material
condition of the aircraft.
4. Maintenance Requirement Cards (MRCs)/Maintenance
Instruction Manuals (MIMs): Direct when fuel samples are
to be taken for specific Type Model Series aircraft and
test cells.
5. NAVAIR 00-80T-109: Aircraft Refueling NATOPS Manual.
6. MIL-HDBK-844: Aircraft Refueling Handbook.
Objectives:
The Fuel Surveillance Program:
a. Establishes policy, responsibilities, and
requirements for implementing procedures to maintain a
satisfactory level of aircraft and engine fuel systems
purity.
b.
Standardizes fuel systems contamination prevention
procedures within all Navy and Marine Corps activities.
Background:
In order to maintain a satisfactory level of aircraft and
engine fuel systems purity, both military and civilian
aviation maintenance activities monitor and maintain fuel
surveillance programs for all type model series aircraft
and engine test cells. In commercial and general aviation,
the Federal Aviation Administration (FAA) advises civilian
aviation to develop fuel sampling procedures (Aviation
Circular AC150/5230-4). Similar procedures are used by
Naval Aviation as outlined in OPNAVINST 4790.2G.
Whether a commercial or military application, fuel quality
has a direct bearing on the condition of aircraft and
engines. Stringent requirements are applied to aircraft
fuel quality due to aircraft high performance criteria and
safety of flight constraints. Proper Fuel Surveillance
prevents the harmful effects of fuel contamination which
include erratic or incorrect fuel quantity indications,
fuel system icing, and damage to engines and fuel system
components. Even though filters are installed in the fuel
systems of aircraft and support equipment, contamination
can still occur. Condensation of moist air can introduce
small amounts of free water in empty or partially filled
fuel cells/tanks. Microbiological organisms can grow if
free water is present. Also, particulate matter
contamination may be generated within fuel cells/tanks and
lines or be introduced during maintenance. Even minute
amounts of dirt and water in fuel can cause aircraft
engines to fail with possible injury or loss of life and
very high repair or replacement costs. For example, if
fuel contamination results in an engine flame out, damage
to the aircraft may be incurred or the engine may require
replacement. In the case of an F/A-18C squadron, the cost
of an engine repair/replacement, loss of aircraft due to
mishap, or defueling for maintenance action is as listed
below:
F404-GE400 engine (Material)
Average AIMD Repair Cost:
$
84,700.
Average Major Depot Repair cost:
403,000.
Average Regular Depot Repair cost:
253,000.
Replacement cost:
1,800,000.
Average Manhours to
Remove/Replace engine:
(4 Pers/5 hrs)
Average Manhours to
Repair Engine at AIMD:
F/A-18C Aircraft
Cost to replace:
Cost to defuel:
Fuel (12,800lbs)
Manhours (2 pers/3 hrs)
20 Hours
67 Hours
$35,000,000.
1,220.
6 Hours
As a precaution against damage from fuel contamination,
aircraft maintenance personnel and test cell operators must
regularly inspect for water and foreign matter in fuel
cells/tanks. For aircraft, fuel samples are taken as a
part of the Daily/Turnaround Inspection or after
maintenance to fuel cells per MRC/MIM. For engine test
cells sampling is conducted weekly. In both cases, an
individual fuel sample is drawn from the lowest point on
the engine or fuel tank, normally a pencil drain, into a
glass container. The sample is then visually inspected for
a clear bright appearance per reference 5 by swirling and
checking directly below the vortex for any discoloration,
water, cloudiness or sediment. If a sample indicates
contamination, it is retained and a second larger sample,
not less than one gallon, is taken. If contamination is
still present, the aircraft or test cell is downed for
maintenance.
Effectiveness:
During calendar year 1999, Type Commander Aviation
Maintenance Management Team evaluators conducted a survey
throughout several type/model/series aircraft. In each
activity, the fuel sample logs indicate that contaminates
are being identified prior to aircraft/engine use. The
most common contaminant was water with all types of
contamination detected.
Recent Aviation Maintenance Management Team visits to
activities have identified only minor program
administrative related discrepancies. The activities’
compliance with program requirements has been satisfactory.
The requirements of the NA 01-1A-35 and the specific
publications/directives are sufficient enough to maintain
fuel systems/equipment in satisfactory condition. The fuel
samples are taken as required by the Type/Model/Series
(T/M/S) MRCs. Completion of the daily inspection and the
amount of fuel in the tank is recorded on the Aircraft
Inspection and Acceptance Record (OPNAV 4790/141).
Completion of the MRC card requiring the fuel sample as
part of the daily/turnaround inspection is documented on
the Daily/Turnaround Maintenance Record (OPNAV 4790.38).
These records have proven to be sufficient for trending
purposes at the activity level.
The Navy Safety Center compiled data for aircraft mishaps
provided below indicates that the emphasis on safety of
flight in this and all NAMP programs has resulted in a
declining number of aircraft mishaps fleet wide over the
last decade.
NAVY/MARINE
CLASS A FLIGHT MISHAPS
FY89 – FY99*
ALL MODELS
YEAR
FY 89
FY 90
FY 91
FY 92
FY 93
FY 94
FY 95
FY 96
FY 97
FY 98
FY 99
TOTAL
EXPOSURE
2,306,414
2,201,634
2,154,079
1,962,943
1,865,702
1,675,241
1,656,450
1,650,026
1,523,507
1,518,109
1,527,186
20,041,291
# EVTS
51
66
60
55
53
28
34
36
27
36
22
468
RATE
2.21
3.00
2.79
2.80
2.84
1.67
2.05
2.18
1.77
2.37
1.44
2.34
The effectiveness of the Fuel Surveillance Program is
measured in the mishap program data. Specific data on the
mishaps in which contaminated fuel was shown as a possible
contributor is outlined below. The data shows only those
hazards where contamination was discovered when fuel
samples were taken.
Class of
Mishap
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000
A
B
C
HAZARD
2
2
3
2
1
1
Analysis:
The Fuel Surveillance Program requirements are listed
below. The responsibilities are listed by the individual
within a squadron or intermediate level maintenance
facility who is responsible for completing the task and
classified into the four categories requested. The manhour
estimates are based on a 10-12 aircraft F/A-18C squadron
with 180 sailors assigned. The manhours required at the
intermediate level of maintenance (AIMD/MALS) is
significantly less, since the equipment being monitored
includes only engine test cells.
PROGRAM ELEMENT
ELEMENT
IMPACT
The Maintenance Officer (MO):
Manhours
expended
-Designate, in writing, a Fuel Surveillance
Program Manager. The Line/Power Line Division
Officer or CPO/NCOIC is recommended for Olevel activities. The Power Plants or SE
Division Officer or CPO/NCOIC is recommended
for I-level activities. (1 designation/yr)
Admin:
<.001 hours
per day.
-Coordinate with the NATOPS Officer to ensure
all aircrew are thoroughly trained in fuel
sampling requirements and procedures while
operating away from home base. (each time a
new NATOPs Officer is designated. 1/yr)
-Develop local command procedures. (1
time/chgs as required)
The Program Manager:
Administrative:
-Be knowledgeable of NAVAIR 01-1A-35, NAVAIR
00-80T-109, MIL-HDBK-844(AS), applicable MIMs,
MRCs, NATOPS procedures for their assigned
aircraft or test cell, and the NAMP.
-Coordinate with the Assistant Maintenance
Officer (AMO) to develop training oriented to
the type of aircraft/test cells operated. (1
time/chgs as required)
-Document training in the individuals training
record. (5 min per record)
-Maintain a program file to include, a list of
all assigned equipment requiring fuel
sampling, applicable points of contact,
program related correspondence and message
traffic, and applicable references or cross
reference locator sheets. (30 min/month)
Manhours
expended
Admin:
<.1
Train:
<.05
hours per
day.
-Review audits and reports to aid in assessing
the program. (2 hr/month)
-Establish a Fuel Sample Log Sheet for each
aircraft/test cell assigned. All samples shall
be logged and the forms maintained on file for
3 months from date of last entry.(30 min/wk)
Training:
-Provide indoctrination and follow-on training
to personnel relating to their
responsibilities regarding the Fuel
Surveillance Program. (initial training 1 hr
per individual and follow-on as req.)
The Quality Assurance Officer:
-Designate, in writing, the Power Plants
Quality Assurance Representative (QAR) as the
Fuel Surveillance Program Monitor.
(1 designation/yr)
The Program Monitor:
-Perform annual program audits and quarterly
workcenter audits using the Computerized SelfEvaluation Checklist. (as required)
-Notify Maintenance/Production Control
whenever fuel contamination is suspected.
Manhours
expended
ADMIN:
<.001 hours
per day.
Manhours
expended
ASSESSMENT:
<.05 hours
per day.
-Quality Assurance (QA) shall conduct an
immediate investigation of aircraft/test cell
fuel systems to determine source of
contamination. If the source is not limited to
a particular aircraft/test cell, the refueling
source shall be determined and the
station/ship Fuels Officer/Supervisor
immediately notified and provided a sample for
analysis. (as required)
Maintenance/Production Control personnel:
-Notify QA and issue a downing discrepancy
against the aircraft or test cell until the
fuel system is determined to be free of
contamination. (as required)
-When embarked, ensure fuel samples are drawn
and analyzed for flash point and the
precautions are followed whenever an aircraft
Manhours
expended
Operation:
.01 hours
per day.
or test cell receives, or is suspected of
receiving, any fuel other than JP-5. Notify
flight deck control not to move the aircraft
to the hangar bay until the flashpoint has
been certified to be above 120 degrees
Fahrenheit. (as required)
-Debrief aircrew returning from cross-country
flights to verify specific fuels used. (as
required)
-Ensure fuel systems of preserved aircraft and
test cells are monitored. Ensure a QAR
inspects fuel cells/tanks for Foreign Object
Damage (FOD) and contaminants immediately
prior to closing (after maintenance has been
performed).
-Ensure adherence to limitations regarding
interchangeability of various grades and types
of fuel. (as required)
Material Control personnel:
-Include Fuel Sample Log Sheets in every
flight packet. Forward used Fuel Sample Log
Sheets to the Program Manager when flight
packets are returned. (as required)
Manhours
expended
Admin:
<.001
hours per
day.
The Line/Power Line (Plane Captain Branch)
Supervisor and Test Cell Supervisor:
Manhours
expended
Operational:
Operation:
<.5 hours
per day.
-Ensure only properly trained personnel
perform fuel sampling. Ensure personnel
adhere to all procedures and safety
precautions. (as required)
-If relatively large quantities of water or
particulate matter are present (compared to a
normal sample) or small amounts persist in two
samples or from other low point drains, notify
Maintenance Control/Production Control
immediately. (as required)
-Retain contaminated samples for inspection by
a QAR or Power Plants Collateral Duty QAR.
Initiate a downing discrepancy when abnormal
amounts of water or contaminants are present
Admin:
<.3 hours
per day.
during sampling. (as required)
Administrative:
-Maintain accurate and up-to-date Fuel Sample
Log Sheets. (30 min/wk)
-Insure adequate supplies of authorized
sampling equipment and protective equipment is
on hand. (as required)
The Power Plants and Test Cell Supervisor:
Operational:
-Ensure integrity of fuel systems during
routine maintenance, including covers/caps on
open or removed fuel cells, lines, and
components.
-Ensure non-RFI and inactive fuel cells/tanks
are properly preserved and protected against
contamination.
Manhours
expended
Operation:
< .2 hours
per day.
Assessment:
< .001
hours per
day.
Assessment:
-If contamination is present, assist QA in
conducting an immediate investigation of the
aircraft/test cell fuel system and components
to determine the source of contamination. If
the source of contamination is not isolated to
a particular fuel cell/tank, the refueling
source shall be determined and the cognizant
activity Fuels Officer/Supervisor notified.
(as required)
Plane Captain/Aircrew personnel:
Operational:
- Accomplish fuel sampling per NAVAIR 01-1A35, MIMs, MRCs, or applicable Air Force, Army,
or FAA approved equivalents when away from
home. For most aircraft this occurs on a daily
basis and weekly for the test cell.
Additionally, as required for subsequent
maintenance on a fuel cell.
-Accomplish fuel sampling properly. Be
thoroughly familiar with fuel sampling
requirements/procedures and contamination
Manhours
expended:
Operation:
< 1.0
hours per
day
Admin:
< .25
hours per
day
identification prior to any flight.
Train:
(15 min/Aircraft/average 4 aircraft/day)
< .001
hours per
day
- Notify Maintenance Control when fuel other
than JP-5 has been used or fuel specific
gravity setting has been adjusted. Ensure
adherence to limitations on interchangeability
of various grades and types of fuel. (as
required)
Administrative:
-
Log all fuel samples on the Fuel Sample Log
Sheet. Be thoroughly familiar with approved
emergency fuels and limitations regarding
interchangeability of fuel types and grades.
(5 min/aircraft)
Training:
- Aircrew involved in HIFR operations must be
trained to perform inspection of fuel samples
per NAVAIR 00-80T-109 prior to commencing
HIFR. (as required)
Total hours per day:
Administrative= 0.653
Training=
0.051
Operational=
Assessment=
0.051
1.71
Total hours
per day:
2.465
Recommendations:
This is a crucial program to the safety of Naval Aviation.
It requires very little time on the part of any individual
involved in any of the processes until contamination is
discovered. Failure to maintain this program could lead to
an increased workload for the fleet sailor due to an
increased number of engine repairs and removals and an
increased risk of mishap. Due to safety of flight elements
and potentially high repair cost, it is recommended that
the Fuel Surveillance Program not be deleted from the OPNAV
4790.2G and that all program requirements be retained with
the exception of those NAMP changes already submitted.
A NAMP Change has been submitted to eliminate the
requirement for the 90 day fuel sample log maintained by
the line division. The data is being tracked in the
Aircraft Discrepancy Book (ADB) for the last ten aircraft
flights. There is no additional value provided by
compiling the data for an extended period. The fuel sample
is a situational inspection with a Go/No-Go criteria for
acceptance. It is either acceptable or unacceptable. The
data is not trended for deteriorating quality. An aircraft
is either safe to fly or not. This NAMP change would
reduce the administrative manhours by .46 per day at the
organizational level.
CURRENT INTIATIVES:
In the future, it is planned that NALCOMIS optimized
upgrade will incorporate the capability to automatically
compile and track the fuel surveillance data currently in
the ADB. NALCOMIS is the primary Maintenance
Information/Data System for aviation maintenance and
supply. The Optimized NALCOMIS system for the
organizational level has been prototyped on both coasts and
fleet implementation is scheduled to commence 4th Qtr FY00.
The Optimized NALCOMIS upgrade will greatly reduce the
manhours required for administrative tasks in not only this
program but all NAMP program areas through the effective
use of a relational data base and real time up line data
replication.