TITLE OF PRESENTATION

Safety Precautions Aircraft and Workshop

By Capt R Harpal Singh
1
 Module 7.1
Safety Precautions

2
 Learning Outcome

At the end of this lesson the students will be able to:

1. Identify the classes of fire and the different types of

extinguishers .
2. Observe the fire safety protection.
3. Observe the safety precautions and procedures when
working with gases, electricity and oils.

3
 Introduction to Safety Precautions

• Aviation maintenance areas are very dangerous

places to work!
• Always wear the correct Personnel Protective
Equipment (PPE) for the task.
• Only operate the tools and equipment we are familiar
with.
• Good housekeeping
• Pedestrian walkways and Fire Lanes should be clearly
marked and ALWAYS kept clear.
• Clean up spillage's immediately to prevent possibility
of fire and injury.
• Know the Locations of First Aid stations and Fire
Fighting Equipment.
4
 Fire

Fire requires four

components to burn.

•Fuel

•Oxygen

•Heat

•Chemical chain reaction

5
 Essential Elements for Fire

• Fuel can be combustible Gas, Liquid or Solid.

• Oxygen in sufficient volume to support combustion.

• Heat requires sufficient intensity to raise the

temperature of the fuel to its ignition point.

• Chemical Chain Reaction an exothermic chemical

reaction in the material.(An exothermic reaction is a
chemical reaction that releases energy by light or heat)

6
 Classes of Fires
• Class A: Solid fires - paper, wood, textiles and general
rubbish.
• Class B: Flammable liquids & solids fuels, alcohol, oils,
greases and oil-based paints and waxes.
• Class C: Natural Gas and Liquid Petroleum Gases such as
LPG- Butane and Propane.
• Class D: High intensity metals - magnesium, potassium,
sodium, titanium and zirconium. Greatest hazard when
they are either in liquid (molten) form, or in finely
divided forms such as dust, chippings, turnings or
shavings.

7
• Electrical: electrical fires are not considered to
constitute a fire class of their own, as electricity is a
source of ignition that will feed the fire until
removed. When the electrical supply has been
isolated the fire can be generally treated as a ‘Class
A’ for extinguishing purposes

• Class F: High temperature cooking oils. Wet chemical

extinguishers have been formulated to deal with this
type of fire.

8
9
 Extinguishing the Fire

We can extinguish a fire by:

• Cooling the Fuel.

• Excluding the Oxygen.

• Separating the Fuel from the Oxygen.

10
 Fire Extinguishants

The following materials are used in fire extinguishers that

conform to BS EN3 standards:

1. Water - (Water/Gas)

2. Aqueous film Forming Foam - (AFFF)

3. Carbon Dioxide - (CO2)

4. Dry Powder

11
 Extinguisher Identification & Use

EXTINGUISHANT BAND TYPE OF FIRE

COLOUR
• Water Red Solid Material. Not for electrical
or flammable liquids.
• AFFF Cream Oils, Paints, Petrol. NOT save
on electrical fires.
• CO2 Black Gases, Electrical, Flammable
Liquids & Solids but not
burning metals.
• Dry Powder Blue Burning Metals, Flammable
Liquids and electrical
(<1000 V, >1 m)fires
• Wet Chemical Yellow Cooking Oils

12
 Water/Water Gas Extinguishers

• Use on Solid Fires ONLY!

• Safety required for the following:
• Do NOT use on Liquid Fires, as it will
cause the Fire to spread.
• Do NOT use on Electrical Fires, as the
water will act as a conductor and
electrocute the fire fighter, You!
• Do NOT use on Burning Metal Fires
as the oxygen in the water will cause
the fire to burn more fiercely, and
may also cause an Explosion.

13
 Aqueous Film Forming Foam (AFFF) Extinguisher

• Use on Solid and Liquid Fires (Class B).

• Smothering action removes the oxygen
and cools the fuel.
• Do NOT use on Electrical Fires, as the
foam contains water, so it will conduct
and electrocute.
• Leaves a messy foam residue which
may be very slippery.

14
 Carbon Dioxide (CO2) Extinguisher

• Suitable for Class A, B and C types of fire.

• Non corrosive, non conductive and leaves no residue.
• Do NOT use on (Class D) Metal fires as it can reduce
temperature very quickly and cause explosions.
• Utilises a horn device to help concentrate the gas at
the site of the fire.
• Do NOT hold the horn during use as freezing burns
may result.
• Rubber insulated tube is provided to assist in directing
the horn at the base of the fire.
• Suitable for engine intake and carburettor fires.

15
Carbon Dioxide (CO2) Extinguisher

16
 Dry Powder Extinguisher

• Suitable for All Classes of fire, but with

limitations when used on Electrical
fires.
• Do NOT use on Electrical fires when
the voltage is greater than 1000 volts.
• Or the distance to the fire is less than
one metre.
• Particularly useful in dealing with
burning metals on aircraft wheel brake
fires.
• Leaves a messy residue which may
cause problems with electrical circuits
and contacts.
17
 Older Types of Extinguisher

• Halon (Halogenated Hydrocarbons)

type extinguishers may still be found in
door location.
• Extinguisher Body All Green in colour.
• Excellent extinguishing properties for
all classes of fire.
• Unfortunately, also very good at
depleting the Earth’s Ozone layer
(phased out).
• Buckets of dry sand may also be found
at Fire Points in workshops as an
additional fire fighting aid. (see video
KLMUK book)
18
 First Aid Information

All staff should know:

•The location of the First Aid Points

•The methods of calling for help
•The locations of alarm bells, and the siting of appropriate
telephones which may be used to summon help in an
emergency
•The identity of the trained First Aid personnel in their
vicinity
•Injuries should be reported i.a.w RIDDOR 95, which is
the Reporting of Injuries, Disease and Dangerous
Occurrences Regulations.
19
 Learning Summary

Fire:  A fire needs four elements to flourish

•1. Fuel
•2. Oxygen
•3. Heat
•4. A Chemical Reaction

•Different classes of fire require different fire extinguishers

and each of these extinguishers are identified by different
colors.

20
Thank You

21
 Exercise

• Identify the type of fire extinguisher to be used for a

fire caused by paper, textile or wood_________.
• The type of extinguisher to be used for burning
metals, flammable liquids and electrical fire
is_________.
• Fire on landing gear brake should be extinguished
with_________ extinguisher.
• Neither oil nor grease should be used as a lubricant
on couplings or pipelines carrying_______.
• The colour of CO2 type fire extinguisher is________.

22
 Typical Essay Questions

1. Describe the four classes of fire and the types of

extinguishers used to put out each fire type.
Include the dangers that may arise if the wrong
extinguisher is used on each class of fire.

23
 Module 7.1
Workshop and Hangar Safety

24
 Learning Outcome

At the end of this lesson the students will be

able to:

1. Observe the safety precautions and procedures on

aircraft and in workshop pertaining to machineries,
electricity, noise, gases and chemicals .

2. Understand the safety to be applied when lifting

and jacking aircraft.

25
 Accidents involving Machinery and Personnel

Personnel can be injured by:

•Coming into contact with machine.

•Being trapped between machine and material.
•Being struck by the machine or parts being ejected
from the machine.
•Becoming entangled in it’s motion.
•Receiving an electric shock from the machine.

26
 Electricity Safety

• The Human Body will conduct Electricity.

• It can cause burning.
• It can disrupt the nervous system.
• Normal 220 - 240 volt/50 Hz domestic power supply
is particularly dangerous.
• Use of a safety cut-out and three core cable will help
minimise the possibility of an electrical accident.
• Do NOT use electrical equipment in the vicinity of
water.

27
 Harmful values of Electricity
Voltage/Current Possible Outcome
50V ac or 100V dc May give rise to dangerous shocks

1 mA Harmless tingle
1 – 12 mA Painful, but can be released
12 – 20 mA Very painful, cannot be released

20 – 50 mA Paralysis of respiration
> 50 mA Heart stoppage

28
29
 Main Causes of Electrical Problems

• Ignorance and carelessness.

• Inadequate or non-existent earthing.
• Worn or damaged wiring, insulation, plugs and
sockets etc.
• Bad wiring systems and misuse of good systems.
• Incorrect fuses.
• Inadequate inspection and maintenance of electrical
tools and equipment.

30
 Precautions with Electricity

• All electrical equipment is subject to regular checks

for correct operation and electrical safety.
• Dated label indicates the test has been completed
satisfactorily.
• It also shows when the next test is due.
• Checks should include damage to wire, plug and
body as well as the safety label is in date.

31
A person receiving an electric shock, should follow the
basic actions:
•Shout for help and ensure there is no danger of also
becoming a victim
•Switch off the electrical current or remove the victim
from the supply by means of insulated material
•If the victim has ceased breathing, initiate resuscitation
•Call for professional medical help
•If the victim is suffering from burns, exclude air from
wounds
•Treat for shock by keeping the victim warm
•The approved methods of artificial resuscitation must, by
law, be displayed on wall charts in workplaces.
32
 Noise Hazards

• Aviation maintenance workshops, hangers and flight

lines can be very noisy places to work.

• Ear protection should be worn to reduce damage

caused by loud noises.

• Noise levels < (below) 85dB - protection is optional.

• Noise levels > (above) 85dB - protection is mandatory.

33
 High Pressure Gases - Safety

• Cylinders are source of high energy, so handle with care.

• Eye protection should always be worn.

• Only use cylinders that can be positively identified.

• Ensure stem cap is fitted when moving a cylinder.

• Ensure cylinders are secured to the transport trolley.

• Always use correct regulator.

• Do not use compressed gas to blow away dust or dirt, and never direct
high-pressure gas at a person.
34
• Concentrated stream of high-pressure gas can penetrate cuts
and wounds in the skin.

• Release compressed gas slowly, as rapid release may cause

hose to whip about or build up a static charge.

• Keep cylinders clean, petroleum based products on an oxygen

cylinder can cause explosions.

• Aircraft tyres operate at very high pressures.

• They are normally inflated inside a cage to protect personnel in

the event of a tyre or wheel bursting.

35
 Gas Bottle Identification

• Most common gases used on commercial aircraft are

nitrogen and oxygen

• Identification is achieved by colour coding the bottles

and writing the name of the gas on the side.

36
 Nitrogen Gas Cylinder Identification

NITROGEN
N2

• Nitrogen gas cylinders are painted grey with a black neck.

Mainly used in tyre inflation & Accumulator because it is an
inert gas
• The words NITROGEN are stencilled on the cylinder body.
37
 Oxygen Gas Cylinder Identification

O2 OXYGEN

• Oxygen gas cylinders are painted black with a white

neck.
• The words OXYGEN are stencilled on the cylinder body.

38
• BS EN 1089:3 is the standard to determine the
correct colour and shade for each gas type.

• US manufactured oxygen bottles uses green colour.

• Medical grade oxygen should not be used in place of

aviation oxygen because it has a higher moisture
content which may freeze at high altitudes.
 Gas Replenishing

• A fully charged nitrogen gas cylinder contains about

200 bar (3000 psi).

• A Boeing 737 main tyre pressure is approximately 7

bar (100 psi).

• The high cylinder pressure must be reduced to the

lower pressure of the tyre in a safe manner.

40
• A number of gas bottles are usually stored on a
trolley, which incorporates a pressure control and
regulating valve as well as an isolating valve.

• A second regulating valve is used at the tyre or

component end for safety and convenience.

• The transfer of high-pressure gases from a large

storage bottle to the aircraft component is often
called decanting and must be done at a very slow
rate. If the gas is decanted rapidly the temperature
of the receiving component will increase in
accordance with the gas laws.
41
• If one of the control valve fails, then the second will
prevent the receiving component or tyre from being
inflated to full bottle pressure.

• This allows the operator to quickly isolate the bottle

should a problem occur.
A typical Cylinder Trolley

43
 Oxygen System
• Smaller aircraft can carry oxygen in cylinders whilst
the larger, civil aircraft have individual chemical
oxygen generator (COG) units.

• These units are stowed in the overhead cargo bins,

above the passenger seats, and are known as the
passenger service units or PSUs. These COG’s
produce oxygen, by means of a chemical reaction,
and is activated when its mask (which drops from the
overhead bin in an emergency) is pulled by a
passenger.

44
 Oxygen Gas Safety
• Aircraft utilise more than one type of gas.

• Important that we do not inflate tyres with Oxygen or the

emergency breathing oxygen bottle with Nitrogen.

• Oxygen cylinders often use left-hand threaded valves to reduce

possibility of charging with incorrect gas.

• High percentages of oxygen in a restricted space can increase

fire risk and burning intensity.

• Petroleum based products and oxygen can produce an

explosion.

45
 Aviation Oils and Fuels
• All petroleum based products have an ignition temperature or
flash point.

• Aviation fuels ignite at a low temperature, with oils and greases

a much higher one.

• Ensure no naked flames are used or generated.

• Torches and strip lights must be flame proof.

• Sweeping fuel with a dry broom may cause build up of static

electricity, and consequences of fire.

• During aircraft fuelling operations the correct quantity and type

of fire extinguisher should be immediately available.
46
 General Safety - Oils and Fuels
• Toxic vapours may be produced by these products.

• Particularly dangerous in an enclosed space.

• Use of masks and respirators may be required.

• Regular contact of the skin with oils and fuels cause dermatitis.

• Use barrier cream and gloves prior to handling.

• When finished wash hands thoroughly and use after work

cream to restore pH balance in hands.

• Some oils and fuels can be detrimental to paint, plastic,

adhesives and sealant’s.
47
 Chemical Hazards
• Chemical compounds can be dangerous to humans.

• Precautions taken vary with each compound type.

• Control of Substance Hazardous to Health (COSHH) Regulations

ensure relevant safety precautions are available for all
compounds used.

• Toxic vapours may be produced by some products.

• Particularly dangerous in an enclosed space.

• Respiration and hand protection may be required.

• Greater risk of fire when using these products.

48
 Low Level Physiological Hazards
• Some aircraft materials are mildly radioactive.

• Emit very little radiation in normal circumstances.

• Commonly known as ‘Heavy Metals’.

They can be found in:

• Balance-weights

• Smoke detectors

• Luminescent ‘EXIT’ signs

• Instruments 49
 High Level Physiological Hazards

• Non-Destructive Testing (NDT) procedures employ high levels

of radiation.

• NDT can only be done by specialised trained personnel.

• Many NDT procedures completed with minimal personnel in

attendance.

• Special monitoring procedures for those involved in NDT is

similar to hospital X-ray departments.

• Manuals give the safety precautions to be observed for the

different testing procedures.

50
 Lifting and Shoring of Aircraft

• Aircraft need to be raised from the ground for certain

maintenance tasks.

• Usually achieved by raising the aircraft on jacks using special

adapters.

• Position of the adapters and jacks decided by manufacturer.

• Adapter points usually located in a tricycle arrangement.

• Typically one at nose and two around central fuselage area -

but not always!

51
Typical Aircraft Jacking Points

Avro RJ/ BAE 146 Fokker 70/100

52
 Lifting Aircraft

• Aircraft jacking requires preparation.

• Only done with correct number of trained, qualified

and authorised personnel.

• Use correct jacks for aircraft - ensure they do not

exceed jacks maximum capacity (SWL).
Other places where Large Jacks are connected
• Under the wings, at the main spar position
• Under the nose
• Under the tail assembly
• On the side of the front fuselage (in place of the
nose jack) 53
54
 Aircraft Jacks - Feet Layout

Feet

Hydraulic Ram

TRIPOD QUADRUPOD

BIPOD
55
 Lifting part of Aircraft

• Certain maintenance tasks only need one part of aircraft raised

- wheel change.

• Achieved by use of dedicated wheel change jack. (Bottle Jack).

• Never simultaneously raise both main legs with the wheel

change jacks.

• Always follow instructions iaw AMM.

• Wheel change jacks usually hydraulic with safety screw lock on

jack body.

56
 Nose or Main
Wheels
Extension on
landing gear bogey
sits in top of jack

Pistons on jack
extend to raise
the aircraft

Wheel change jack slides in between aircraft wheels

 Shoring (Supporting)

• Supports are sometimes

required to steady an
aircraft.
• These supports are known
as Trestles.
• Used to prevent unbalance
during maintenance.
• Can also be used to support
large components such as
wings and tail planes.
F-100 Tail
Trestle
Position

58
 Typical Trestle

Wood beam helps

prevent damage to
aircraft structure

Ratcheting Threaded
Handle for rod
Height
Adjustment

59
 Slinging

• Slings are used to lift whole aircraft, sections of aircraft and

major components such as wings and engines.

• Only the approved manufacturers sling should be used to for

that component.

• This ensures the correct C of G is always maintained.

• Correct sling will be identified by part number.

• PPE - AMM dictates requirements but should include hard-hats.

60
 Learning Summary

• Workshop and Hangar Safety:  It only takes 50mA to stop a

persons heart - be careful around electricity. 
• Remember Personal Protection Equipment (PPE) is supplied for
your safety.
• Working with Oxygen equipment must be done in a clean
environment without the use of oils and greases, which may
cause explosions. Therefore only use approved lubricants.
• Precautions need to be applied when using high pressure gas
cylinders. Decant slowly using the correct gas.
• When carrying out a lifting operation ensure the
correct authorized sling is used and it is positioned over the
center of gravity of the load.

61
Thank you

62
 Questions

• Ear protection is mandatory, when the noise is

greater than _____.
• What is the color of an oxygen gas bottle.
• Why spilled fuel should not be swept with a broom.
• Name some areas where you will find materials that
emits mild radiation.
• What is the purpose of the safety locking collar on
the jacks used for.
• What type of jack is used, when one wheel is to be
removed.
• What is to be used, when the aircraft need to be on
jacks for longer periods.
63
 Module 7.1
Flight-Line Safety

64
 Learning Outcome

At the end of this lesson the students will be able

to:
1. Carry out towing and parking.
2. Refuel an aircraft.
3. Carry out marshaling.

65
 Flight-Line Safety

• A Flight-Line (Ramp) is a dangerous place to work.

Some of the dangers are as:

• Tripping over cables and hoses.

• Hit moving and catering vehicles, control surfaces & pitot probes.

• High noise levels so reduced verbal communications.

• Being sucked into an engine intake.

• Being burnt or blown over by the engine exhaust.

• Being hit by a propeller.

66
Flight-Line Safety - Propellers

Normally < 1 m

Accidents involving propellers

are usually always fatal!
67
 Flight-Line Safety - Propellers

• Accidents involving propellers are usually always

fatal.

• Always treat a stationary propeller as live.

• Propellers sometimes have markings which makes

them highly visible whilst spinning. (Can range from
yellow, white and black colour)

• AMM’s show suggested walkways to avoid the danger

areas posed by propellers.

68
 100m
100°C

75 m
Jet 300°C

Aircraft 50 m

Danger 500°C

Areas 25 m

700°C

0m

0m

Approximate values
10 m
69
 Towing & Taxing
All operators, aircraft and airports have specific rules which must
be adhered to when towing: The common ones are:

•Maximum towing speed (5 mph or walking pace).

•Minimum turning radius.

•Route to be taken to destination.

•Airfield radio call sign.

•Type of towing vehicle.

•Correct towing arm for that aircraft.

70
 Safety when Towing

• Towing an aircraft requires the correct number of trained,

qualified and authorised personnel.

• Unobstructed communication’s required between all team

members.

• Towing team need the correct PPE such as:

1. High visible jackets.

2. Ear protection.
3. Cold weather clothing (optional).

71
72
 Parking of Aircraft

• Precautions need to be taken with aircraft parked for short

periods.

• Chocks positioned on both sides of one or more of the wheels.

• Blanks fitted to engine intakes and exhausts.

• Bungs fitted to holes for pitot and static vents.

• Similar bungs and blanks fitted as dictated by AMM.

• Control locks fitted or engaged.

73
Rich, here’s one our team did this morning. Tell Carl &
T.O. there lucky they are not the flight chief’s of this
one. Here’s the pictures on the seriously damaged
KC-10 at hangar 810 and hangar 818 area. please
stay away for now since the aircraft is impounded by
the IG. the accident occurred because the tow team
DID NOT follow tech data procedures. The tow
team disconnected the yoke to open the hangar doors
at hangar 810 because it would not open. The tow
team DID NOT chock the aircraft, which rolled down
the embankment and hit the t-tail stand, dragging it
until it rolled over on the dirt area at hangar 818. The
accident caused severe damage to the aircraft! We
MUST pay close attention to detail on our jobs.
Everybody have a safe and good day.

74
75
76
77
78
79
 Marshalling

• Personnel who are required to Marshall aircraft need to know

the required signals.

• Marshalling an aircraft can only be done by trained, qualified

and authorised personnel.

• Marshalling batons or wands for hours of darkness.

• They need correct PPE for the task such as:

1. High Visibility Jackets.

2. Ear Protection.
3. Safety Boots/Overalls.
4. Cold/Wet Weather Clothing or Sun Protection.
80
 Standard Marshalling Signals

Come Ahead Stop

(Crossed Hands)

Emergency Stop
Repeat Open & Cross Hands 81
 Standard Marshalling Signals

All Clear (OK)

Left Turn Right Turn

82
 Standard Marshalling Signals

Slow Down

Insert Chocks
Remove Chocks 83
 Fuelling

• Various types of aviation fuels are available for

different aircraft types.

• Correct type of fuel is marked adjacent to aircraft’s

refuel point.

• The Fuel Bowser (Fuel Truck) should have the same

fuel identification symbol as the aircraft.

• Fuel bowser parked as far as possible from aircraft

and positioned to enable rapid removal in an
emergency.
84
• Electrical bonding between aircraft and bowser, and
between fuel hose and aircraft.

• Safety zone as dictated by AMM or local regulations.

• Fire fighting equipment readily available.

• No electrical switching or radio/radar operations

during fuelling.

• No naked flames or hot exhausts from APU or GPU.

85
 Weather Radar Safety

• Radiation and localised heating dangers due to

microwave hazard.

• Fuelling operations are NOT to be performed when

ground testing weather radar.

• Observe minimum distance when operating or testing

on the ground.

• AMM will dictate for each aircraft type.

86
 Weather Radar Safety

• Testing usually done with

aircraft facing towards open
airfield.

• Erect barriers with signs to

warn others when testing
the weather radar.

87
 Learning Summary

• Flight Line Safety:  Most tasks you will undertake

involve some sort of training and authorization before
you are allowed to carry them out. Be aware of the
hazards around you, especially on a busy ramp.

88
Thank you

89
 Questions

• The minimum 'No Smoking' zone around an aircraft

when refuelling is_______ .
• What is the minimum speed required while towing an
aircraft.
• The minimum men required during towing _____.
• Why are propeller blades highly visible with colour
markings.
• Why is it necessary to ground aircraft while refuelling is
carried out.

90
 Typical Written Question

• Discuss the various hazards that may cause injury on

an aircraft flight line.

• Include in the answer problems involving noise, high-

pressure gases and Foreign Object Damage.

91