Refuelling Training for Ryanair Group Fleet

Issue 3, December 2021

Originator: Engineering Training
Delivered by Ryanair Engineering
Course Revision Status
Issue Changes Reviewer Date

Review of course material to include updates for B737-800NG, -8200 and

3 Airbus A320 Refueller Training. M Wolfenden 14/12/2021

FOR TRAINING PURPOSES ONLY

Disclaimer
• This course is for training purposes only.

• Always follow the approved

maintenance manual/documentation for
latest updates.

• This training course conforms to

the following AOCs:

FOR TRAINING PURPOSES ONLY

Course Objectives
• Developed in accordance with:

• ICAO Annex 14, Chapter 9 – International and

FAA Fuel Fire Safety

• Boeing 737 NG and 8200 AMM 12-11-00-650

and AMC1 Cat1/op/mpa195

• Airbus A320 AMM 12-11-28 pb301.

Course Objectives
The trainee should, after the completion of the
training:

1. Personnel carrying out the fuelling

operation must know the following:

2. Boeing 737 NG,737-8200 and Airbus A320

fuelling procedure

3. Refuelling supervisor duties

4. Emergency procedure to be followed in the

event of:
1. Fire

2. Fuel spill
Personnel Requirements
Key Roles:

• The ‘Qualified Person’ (EASA REG) in the flight deck is a pilot/engineer who is capable of handling communications, initiating
emergency procedures and directing an evacuation.

• The ‘Fuelling Supervisor’ (EASA REG) is the fuel operator/fueller

• ‘Line of sight’ communications (EASA REG) is required between the fuel supervisor and the qualified person in the flight deck

• The fuel supervisor and the qualified person on the flight deck shall use ‘thumbs up’ signal to each other to indicate line of
sight communication is established and fuelling can commence

Non compliance with the procedure risks SAFA/SACA ramp inspection findings

SAFA = Safety Assessment of Foreign Aircraft

SACA= Safety Assessment of Community Aircraft

FOR TRAINING PURPOSES ONLY

Personnel Requirements
The ‘Qualified Person’ shall also ensure the following:
• The aircraft is suitably immobilised by means of brakes and/or chocks.

• The aircraft is in the correct configuration for refuelling,

• Passengers and Cabin Crew are informed so that Cabin Crew are appropriately positioned for emergency egress procedures.

• Where a passenger boarding bridge is not in use, steps shall be in place at the doors (L1 or L2).

• If advised that fuel vapour is detected within the cabin, fuelling must be ceased until it is safe to resume.

• Remain vigilant for fire or other warning of an unsafe condition via visual communication or headset and be prepared to initiate passenger
evacuation if necessary.

• If a hazard arises, communicate with the refuelling operator to ensure that fuelling shall be stopped immediately until conditions permit resumption.

• Before and during refuelling, where applicable and in consultation with the Dispatcher/GHA, ensure that Fire Service facilities are available.

• Every case of fuel spillage, irrespective of the amount, shall be reported immediately to the Airport Authorities – in this case the flight crew-member
in the cockpit shall notify ATC that a fuel spillage has occurred and shall include details of the aircraft parking position.

Note: When there are no passengers embarking, disembarking or on board the qualified person does not have to
remain in the flight deck.
FOR TRAINING PURPOSES ONLY
Personnel Requirements
Fuelling Operator responsibilities include:
• Ensure that the aircraft is bonded to the refuelling tanker/fuel pit

• Responsible for supervising aircraft refuelling (AMC1 CAT.OP.MPA.195)

• Responsible for liaising with the Flight Crew (i.e. the Qualified Person)

• Responsible for the safe positioning of the fuel truck and awareness / maintenance of the vehicle escape path

• Upon noticing hazards, unsafe acts or incidents – the Fuelling Operator is responsible for notifying the Flight Deck and minimising the risk
to the aircraft, passengers, crew and ground handling team

Note: During refuelling, the aircraft refueller does not need to remain in constant line-of-sight. The flight crew member
visually monitors the refuelling environment. This allows for the aircraft refueller to move between the aircraft and bowser as
part of their normal duties. This may, on occasion, mean that the refueller is temporarily out of sight. However, aircraft
refuellers are trained to, whenever practical, return to a position in which they can be seen from the flight deck.

FOR TRAINING PURPOSES ONLY

Personnel Requirements
PRIOR TO COMMENCEMENT OF REFUELLING

• The pilot completing the walk-around/GHA shall communicate the required fuel uplift to the refueller

• Prior to refuelling, ensure acknowledgement of the Fuelling Operator and the Qualified Person in the flight deck using
and observing ‘thumbs up’. This confirms positive two-way communication and indicates that both parties understand
that the Fuelling Operator will configure the aircraft refuelling control panel and refuelling will commence.

Should it be necessary for both flight crew members to leave the aircraft prior to completion of fuelling, one crew member
shall advise the refueller of whether passengers are still on-board.

FOR TRAINING PURPOSES ONLY

Personnel Requirements
STANDARD PROCEDURES DURING REFUELLING

During refuelling with passengers disembarking, on board, or boarding, a minimum of one flight deck crewmember shall remain
in the flight deck in a suitable position, i.e. right-hand cockpit seat, to maintain visual contact with the fuelling environment.
During the refuelling process, the normal location of the Fuelling Operator is viewable from the cockpit.

In the case of any hazard or incident that may affect the safe conduct of refuelling operations, the following procedure shall
apply:

In order to ensure that the fuelling stops immediately, the Flight Crew shall:
• Attract attention visually with the Fuelling Operator and/or use the ‘GRD Call’ pushbutton

• Open flight deck side window and use direct verbal communication or;

• Dispatch the other flight crew member to the Fuelling Operator on the ramp.

FOR TRAINING PURPOSES ONLY

Personnel Requirements
In the case of any hazard or incident that may affect the safe conduct of refuelling operations, the following procedure shall apply:

The Fuelling Operator shall:

• Ensure that the fuelling stops immediately (prepare to move the bowser away from the aircraft if necessary).

• Attract attention of the Flight Crew by:

a) Banging on fuselage at flight deck position

b) Visual signals (refer to OMA CH 12.6)

c) Using ‘PILOT CALL’ pushbutton

d) Proceeding with verbal communication via open side window

e) Use of headset (if available) or entering aircraft to notify crew directly.

Note: If the above methods of communication are unusable the fuelling operator should attract the attention of a member of the Ground
Operations team. In the event that two-way visual communication becomes unavailable (e.g. a ground handling vehicle blocking line-of-sight)
fuelling shall be suspended until:

• Two-way visual communication is re-established or;

• A nominated flight crew member is positioned on the ground and within easy reach of the system of communication to the other crew
member in the flight deck.
FOR TRAINING PURPOSES ONLY
Personnel Requirements
ALTERNATE PROCEDURES

Where the above standard procedure cannot be implemented due to local restrictions the following alternate procedure shall
apply:
• One Flight Crew member shall remain in the flight deck and within reach of the system of communication (i.e., the Qualified Person).

• Two-way communications shall be established and remain available at all times during the refuelling operation.

• An appropriately trained person shall remain at the aircraft and within easy reach of the system of communication to the flight deck during
refuelling operations with passengers on board (i.e. supervising the refuelling). This person shall advise the flight deck that refuelling is
about to begin or has been completed. This duty may be performed by a Flight Crew member or an Engineer.

The person on the ground will remain within easy reach of the system of communication which implies that the person on the
ground does not have to be on the headset all the time, except in states requiring this. The person on the ground can complete
other tasks providing he can see the refueller and remains within easy reach of the communications system, e.g. completing the
walk around.

FOR TRAINING PURPOSES ONLY

Emergency Procedures – Fire or Fuel Spill Action
1. STOP FUELLING

2. INFORM CAPTAIN

3. ACTIVATE STAND FUEL CUT-OFF

4. CONTACT FIRE SERVICE

5. IF SAFE TO DO SO:
1. DISCONNECT FUEL HOSE FROM AIRCRAFT

2. MOVE FUEL TRUCK AWAY FROM AIRCRAFT

FOR TRAINING PURPOSES ONLY

Fuelling Zone
A. A Fuelling Zone is a hazardous area
which exists around an aircraft
during preparation for and during
fuelling of the aircraft.

B. A Fuelling Zone must:

1. Be approved by the airport
authority.

2. Have fire and rescue service

available.

FOR TRAINING PURPOSES ONLY

Fuelling and Boarding
Alternate Procedure

A. During fuelling & boarding a member of crew will

be positioned in the flight deck and the other crew
member will be on a headset in the vicinity of the
Forward RH ground power connection panel.

B. The Fueller must remain in line of sight of this

person to pass-on any emergency instructions if the
need arises.

FOR TRAINING PURPOSES ONLY

Fuelling and Boarding
1. Obey airport regulations on fuelling with passengers on board (appropriate to that base)

2. Passengers are not to enter fuelling zone which includes 3 metre radius from wing tip fuel vents

3. R1 & R2 door must be manned during fuelling & boarding as the slides may be armed in an
emergency

4. All exits to remain unobstructed while fuelling with passengers on BOARD

FOR TRAINING PURPOSES ONLY

Keep Emergency Exits Clear

External areas adjacent to the R1 & R2 doors to remain clear in the event the emergency
escape slides are activated.

FOR TRAINING PURPOSES ONLY

Maintenance Restrictions
1. DO NOT CONNECT OR DISCONNECT GROUND POWER DURING FUELLING.

2. DO NOT FUEL IF THERE IS AN ENGINE FIRE WARNING – CHECK WITH CAPTAIN OR

ENGINEER.

3. DO NOT SERVICE CREW OXYGEN SYSTEM DURING REFUELLING.

FOR TRAINING PURPOSES ONLY

Ryanair Refuelling

DO NOT REFUEL IF THERE IS ANY

SIGN OF OVERHEATED BRAKES –

Report it to the Captain

FOR TRAINING PURPOSES ONLY

Ryanair Refuelling – Weather Precautions
DO NOT FUEL AIRCRAFT IF THERE IS:

• AN ELECTRICAL STORM WITHIN 10 miles

(16Km), LIGHTNING STRIKES CAN CAUSE:
• SERIOUS INJURY

• FIRE OR EXPLOSION

• STRONG WIND CONDITIONS, WHICH CAN

CAUSE A BUILD-UP OF STATIC ELECTRICITY .

FOR TRAINING PURPOSES ONLY

Ryanair Refuelling – APU Exhaust Precautions
• The APU exhaust must not enter the fuelling zone.

• There must be a minimum of 16 metres separation

between the operating APU exhaust outlet and the
fuel zone.

The fuelling zone includes:

1. The area around the fuel truck .

2. The area around the wingtip fuel vent.

FOR TRAINING PURPOSES ONLY

Ryanair Refuelling – Fuel Truck Precautions

• Make sure there is a clear exit path for the fuel truck at all
times.

• The fuel truck must not obstruct:

1. Passenger emergency exit routes.
2. Emergency exit slide deployment areas.

• The Fuel truck must not be parked in the engine or APU

exhaust of nearby aircraft.
FOR TRAINING PURPOSES ONLY
Ryanair Refuelling
MAKE SURE THERE IS A
CLEAR EXIT PATH FOR THE
FUEL TRUCK AT ALL TIMES IN
CASE OF AN EMERGENCY.

FOR TRAINING PURPOSES ONLY

Ryanair Refuelling
KEEP IGNITION SOURCES CLEAR OF THE
WING TIP FUEL VENTS – FUEL VAPOUR CAN
ACCUMULATE IN THIS AREA.

BOTH THE A320 AND B737 VENTS ARE IN

THE SAME AREA.

FOR TRAINING PURPOSES ONLY

Ryanair Refuelling
• Make sure there is no ground equipment under the wingtip fuel vents.

• Make sure all stands, ladders, vehicles and equipment that can come into contact with the aircraft are removed
clear before the refuel operation starts.

• Chocks and baggage belts must not be tight against wheels or the aircraft as they may become wedged as the
aircraft settles under the added fuel load.

FOR TRAINING PURPOSES ONLY

Fuel Requirements

WARNING: ONLY USE JET A-1

WARNING: DO NOT USE WIDE

CUT FUEL – JET B OR JP-4

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
• PUT THE SAME AMOUNT OF FUEL IN No 1 Main Tank & No 2 Main Tanks.

• 737 NG and -8200: If the centre tank contains > 450 kg of fuel, the No 1 & No 2
tanks must be FULL .

• A320: If the centre tank contains > 250 kg of fuel, the No 1 & No 2 tanks must be
FULL .

• Be aware that dangerous concentrations of fuel vapour exist at the wingtip vent
areas during and after fuelling. FOR TRAINING PURPOSES ONLY
Boeing 737 NG and 8200 Procedure

FOR TRAINING PURPOSES ONLY

Boeing 737 NG and 8200 Procedure

P15 Fuelling Panel

Test Switch /
Door switch
bypass

Quantity
Indicator

Tank Selector
If power is not Switch
available when door is
open
Select & hold Door Fuel Valve
bypass switch Powered
Light
Fuelling Requirements
Fuelling Procedure: Step 1

• Connect bonding cable to the aircraft ground

point at the right mainwheel well.

• Opening the refuel access door on the right wing

this will supply power to the p15 panel. Holding
the test switch to bypass position will supply
power if the panel switch fails.

FOR TRAINING PURPOSES ONLY

Bonding

The Bonding lead attachment point is In the

right- main wheel well.

Attach lead here

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
Fuelling Procedure: Step 2
1. Move the fuel indicator test switch to ‘test gauges’.

1. Verify upper & lower displays reads ‘88888’

2. Release test switch – indication should returns to normal.

3. If the indicator shows ‘FAIL’ - do not refuel until you consult with the captain or engineer.

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
Fuelling procedure: Step 3

1. Press the ‘valve power supply’

lights – to verify ‘blue’ lights
illuminate.

2. Failure to illuminate indicates a

faulty lamp or valve power supply.

FOR TRAINING PURPOSES ONLY

P15 Fuel Panel
Selecting the valve open switch activates the
particular tank valve to open. When the tank
is full you must then select the valve to
closed.
P15 Fuelling Panel

Caution
Fuel
The blue light illuminates to show that power panel
has been supplied to the solenoid on the
Bypass
refuel valve. The valve will only open when Switch
pressure from the Refuel truck or boost
pump pressure is available.

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
Fuelling Procedure: Step 4
1. Check the refuel adaptor before you connect the
fuel nozzle for:
1. Leaks

2. Damage

3. Contamination

If the refuel adaptor is damaged, this can cause a fuel

leak.

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
CAUTION

DO NOT EXCEED 55 PSIG / 379 KPA FUEL PRESSURE

MINIMUM DEFUEL PRESSURE IS – 5 PSIG / -35KPA

SERVICE THIS AIRCRAFT WITH

JET A-1

DO NOT USE WIDE CUT FUELS

(JET B OR JP-4 )
FOR TRAINING PURPOSES ONLY
Fuelling Requirements
Fuelling Procedure: Step 5
1. Connect the refuel nozzle to the adaptor.

2. Calculate the fuel quantity required in each tank.

3. Set the refuel valve switches for the tanks to be refuelled to ‘OPEN’.

4. Start refuelling..

FOR TRAINING PURPOSES ONLY

Fuel Panel
Monitor the Quantity indicators &
select the valves closed when the
desired Quantity has been reached.

P15 Fuel panel Tank 1 and Tank 2 Valves

selected open

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
Fuelling Procedure: Step 6
Caution:

• Monitor the fuel gauges to make sure they do not flash.

Stop refuelling:
• If the fuel gauges flash, stop refuelling immediately. The fuel tank can be overfilled if the fuel gauges flash.

This will cause a fuel spill

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
• There have been a number of fuel spillages during refuelling of aircraft, particularly from the Right Wing Vent
Tank.

• There is a possibility that the Right Wing can experience ‘Stratification’ and the Fuel Quantity Indication can read
slightly low.

• Stratification is explained as cold fuel at the fuel quantity compensator while the tank is refuelled with warm
fuel.

• In this scenario, it is possible that the Fuel Quantity Indication may not flash before a fuel spill occurs.

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
When there is a requirement to refuel to Full Wings (approx 3900Kg), refuelling must be stopped at 3700kg to allow the fuel
quantity indication to settle, and after 1 minute refuel very slowly until 3900 kg is indicated or :-

a. The Fuel Quantity Gauge digits start to flash, OR

b. The Fuelling Valve Open light goes Off whichever occurs first.

When:

a. The Fuel Quantity Gauge starts to flash,

OR

b. The Fuelling Valve Open light goes Off

Do not push the Manual Override Plunger to Top Up the tank.

FOR TRAINING PURPOSES ONLY

Fuelling Requirements
Fuelling Procedure: Step 7

• On completion of fuelling:

1. Stop the fuel truck pump.

2. Disconnect the fuel nozzle adaptor.

3. Close tank switches on the fuel panel.

4. Make sure there is no leaks at the refuel adaptor.

5. Close the fuelling access panel.

6. Remove the bonding cable.

FOR TRAINING PURPOSES ONLY

Fuel Tank Capacity B737-NG
and B737-8200
Tank Quantity
Main Tank No 1: 3,915 KG
Main Tank No 2: 3,915 KG
Centre Tank: 13,066 KG
Total Fuel: 20,886 KG

FOR TRAINING PURPOSES ONLY

Fuelling Instructions – Decal inside panel
A320 Fuelling Procedure

FOR TRAINING PURPOSES ONLY

A320 Procedure
REF AMM 12-11-28-650-003-A

General layout showing location of

tanker , vent areas and bonding lead
attachment point.

FOR TRAINING PURPOSES ONLY

Fuel Requirements A320

CAUTION

DO NOT EXCEED 50 PSIG / 3.45 bar FUEL PRESSURE

DEFUELING REQUIRES USE OF AIRCRAFT FUEL PUMPS

SERVICE THIS AIRCRAFT WITH

JET A-1

DO NOT USE WIDE CUT FUELS

(JET B OR JP-4 )
FOR TRAINING PURPOSES ONLY
 A320 Refuel Panel

STEP 1
Opening refuel panel, this will apply
power

STEP 3
For Automatic Mode STEP 2
Use Rocker switch to set Preselecter to required Hold TEST switch to LTS to
Fuel load Check all lights illuminate
PRESELECTED and ACTUAL
Position Mode Select switch to REFUEL Gauges indicate all 8’s

Commence pumping
When Actual Fuel quantity matches the Preset Hold TEST switch to HIGH this
quantity the Refuel valves will close will check the HI-Level system
automatically and the
END light will illuminate
FOR TRAINING PURPOSES ONLY
Refuelling Point on Right-Hand Wing

After attaching bonding leads

• Remove cap 41QM item C
• Attach refuelling coupling
• Commence fuelling

FOR TRAINING PURPOSES ONLY

Fuelling Requirements On completion of fuelling:
• Stop the fuel truck pump.

• Disconnect the fuel nozzle coupling.

• Close tank switches on the fuel panel.

• Make sure there is no leaks at the refuel adaptor.

• Replace Cap 41QM.

• Close the fuelling access panel.

• Remove the bonding cable.

• Check correct fuel loading.

• If END light is flashing inform Captain/Engineer.

FOR TRAINING PURPOSES ONLY
Fuel Tank Capacities

• Depending on Aircraft serial

Number Quantities may vary.
Tank Quantity
• Typical FULL tank figures are in Left hand wing Inner and 6264 Kg
outer Tank
Centre Tank 6476 Kg
the following table:
Right hand wing Inner 6264 Kg
and outer Tank
• Max Refuelling Pressure 50psi Total all tanks 19003 Kg

(3.45Bar)

FOR TRAINING PURPOSES ONLY

Ryanair Fuelling Requirements

AFTER FUELLING

PROVIDE CAPTAIN OR ENGINEER WITH DETAILS OF FUEL UPLIFT

QUANTITY

FOR TRAINING PURPOSES ONLY

You Have Completed the Training
Section
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End of Training

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the course originator.

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