Module 7.

1

Safety Precautions
Aircraft and Workshop
1
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.
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.
2
Fire
Fire requires three
essential items to burn.

Fuel

Oxygen

Heat

The Fire Triangle
3
Essential Elements for Fire
Fuel can be a 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.
4
Classes of Fire
A Solids

B Liquids

C Electrical

D High Intensity
Wood, Paper and
Textiles.
Oil, Petrol and Alcohol.

Motors, Fuse-boxes and
Wiring.
Magnesium, Titanium
and Sodium.
Classes of fires are determined by the
material being burnt.
5
Extinguishing the Fire
We can extinguish a fire by:

Cooling the Fuel.

Excluding the Oxygen.

Separating the Fuel from the Oxygen.
6
Fire Extinguishants
The following materials are used in fire extinguishers
that conform to EN3 standards:

1. Water (Water/Gas)

2. Aqueous film Forming Foam (AFFF)

3. Carbon Dioxide (CO
2
)

4. Dry Powder
7
Fire Extinguisher Identification
BS EN3 Standard
Extinguisher Body is Red
Coloured sections indicate type
of extinguishant. (5% area)
BS 5423 (Previous) Standard
Extinguisher Body is All One
Colour
Colour Indicates Extinguishant
8
EN3 Fire Extinguisher Identification
Water Red Solid Material
AFFF Cream Flammable Liquids
CO
2
Black Gases, Electrical,
Flammable Liquids
and Solids
Dry Powder Blue Burning Metals,
Flammable Liquids and
Electrical
EXTINGUISHANT

BAND
COLOUR

TYPE OF FIRE
9
Water and Water Gas
Extinguishers
Use on Solid Fires ONLY!
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.
10
Aqueous Film Forming Foam
(AFFF) Extinguisher
Use on Solid and Liquid Fires.
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.
11
Carbon Dioxide (CO
2
)
Extinguisher
Suitable for Class A, B and C types of fire.
Non corrosive, non conductive and leaves no residue.
Do NOT use on 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.
12
Carbon Dioxide (CO
2
)
Extinguisher
13
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 residue which may cause
problems with electrical circuits and
contacts.
14
Older Types of Extinguisher
Halon (Halogenated Hydrocarbons)
type extinguishers may still be found
in some areas (BCF).
Extinguisher Body All Green in colour.
Excellent extinguishing properties for
all classes of fire.
Unfortunately, also very good at
depleting the Earths Ozone layer, and
will be illegal after December 2003.
Buckets of dry sand may also be
found at Fire Points in workshops as
an additional fire fighting aid.
15
First Aid Information
All staff should know:
How to call for Emergency Assistance.
The Location of First Aid Stations and Emergency
Telephones.
The Identity of the Trained First Aid Personnel.
Paperwork must be completed if an injury occurs, no
matter how slight.
Injuries should be reported iaw RIDDOR 95, which is
the Reporting of Injuries, Disease and Dangerous
Occurrences Regulations.
16
1. Describe the four classes of fire and
the types of extinguishers used to put
out each fire type.

2. Include the dangers that may arise if
the wrong extinguisher is used on each
class of fire.
Typical Written Question
17


Any Questions?
18

Workshop and Hangar
Safety
19
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 its motion.
Receiving an electric shock from the machine.
20
Electric Safety
The Human Body will conduct Electricity.
It can cause burning at entry and exit points.
It can disrupt the nervous system and cause a person
to grip a live cable so they cannot release it.
Normal 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.
21
22
Harmful Values of Electricity
Voltage/Current

50V ac or 100V dc
1 mA
1 - 12 mA
12 - 20 mA
20 - 50 mA
> 50 mA
Possible Outcome

May give rise to dangerous shocks
Harmless tingle
Painful, but can be released
Very painful, but cannot be released
Paralysis of respiration
Heart stoppage
23
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.
24
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.
Equipment should be given a pre-use check by the
operator before being used.
Checks should include damage to wire, plug and
body as well as the safety label is in date.
25
First Aid involving Electricity
Shout for help and ensure you do NOT also become a
victim.
Switch off the current or remove the supply from the
victim, by use of insulated material.
If victim has ceased breathing, initiate resuscitation.
Call for professional medical help.
Treat victim for wounds and burns.
Treat for shock by keeping the victim warm.
26
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 damage is cumulative and cannot be regained.
High and low end of hearing range is damaged first.
Noise levels < 85dB - protection is optional.
Noise levels > 90dB - protection is mandatory.
27


Any Questions?
28
High Pressure Gases
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.
Continued...
29
Concentrated stream of high-pressure gas can
penetrate cuts and wounds in the skin.
This can cause an Embolism which may result in
death or brain damage.
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.
End
30
31
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.
Continued...
32
Nitrogen Gas Cylinder
Identification
NITROGEN
N
2

Nitrogen gas cylinders are coloured grey with a black
neck.
The words NITROGEN are stencilled on the cylinder
body.
Continued...
33
Oxygen Gas Cylinder
Identification
OXYGEN
O
2

Oxygen gas cylinders are coloured black with a white
neck.
The words OXYGEN are stencilled on the cylinder
body.
Continued...
34
BS 381C is the standard to determine the correct
colour and shade for each gas type.

Be aware that bottles of US manufacture use an
alternative system.

The main difference being oxygen bottles are painted
green all over.

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.
End
35
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.
Continued...
36
To ensure that 200 bar of nitrogen is not accidentally
decanted directly into an aircraft tyre, a number of
control valves are used.

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.
Continued...
37
If one of the control valves fail then the second will
prevent the receiving component or tyre from being
inflated to full bottle pressure.

As an added safety feature the bottle valve on/off
key, which is located on the gas bottles neck, should
be left in position during decanting.

This allows the operator to quickly isolate the bottle
should a problem occur.
End
38
The Gas Laws
Transferring gas from a storage bottle to an aircraft
component must be done at a very slow rate.
If the gas is transferred rapidly the temperature of
the receiving component will increase in accordance
with the gas laws.
Over a period of time the gas in the container will
drop to ambient, and the pressure in that vessel will
reduce.
The component pressure will now be incorrect and
procedure will need to be repeated.
39
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.
Specially approved lubricants can be used for threads
of oxygen components. (Fombolin)
40
Oxygen Gas Generators Safety
FSCM NO. 16827
EMERGENCY OXYGEN
GENERATOR - 4 PERSON
PART NO. 117022-03
MFG.
DATE
LOT
NO.
INSP. STAMP
PURITAN-BENNETT
AERO SYSTEMS CO.
Outlet to Masks
Firing Pin
Indication Label
41
Oxygen Gas Generators Safety
Emergency breathing oxygen can be stored as a solid
(Sodium Chlorate) as well as a gas.
Chemical Generators contain sodium chlorate.
Ignited by a striker when the mask is pulled down.
Produces gaseous oxygen and large amounts of heat.
These generators must have a safety pin fitted when
a live unit is being removed or fitted to the aircraft.
They are NOT allowed to be transported in aircraft as
freight.
Burning chemical generators, being carried as freight,
have destroyed an aircraft in flight.
42
Fire Safety - 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.
43
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 with oils and fuels can degrease the
skin and 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 sealants.
44
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.
45
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
46
High Level Physiological Hazards
Non-Destructive Testing (NDT) procedures employ
high levels of radiation.
NDT can only be done by specially 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.
47


Any Questions?
48
Lifting Complete 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!
49
Typical Aircraft Jacking Points
Avro RJ/ BAE 146 Fokker 70/100
50
Lifting Complete 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.

Some operators support the aircraft and lower the
floor away!
51
52
Aircraft Jacks - Feet Layout
TRIPOD
BIPOD
QUADRUPOD
Hydraulic Ram
Feet
53
Lifting part of Aircraft
Certain maintenance tasks only need one part of
aircraft raised - wheel change.
Achieved by use of dedicated wheel change 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.
54
Extension on
landing gear
bogey sits in
top of jack
Wheel change jack slides in between aircraft wheels
Pistons on
jack extend
to raise the
aircraft
End
Nose or
Main Wheels
55
F-100 Tail
Trestle
Position
Shoring (Support)
Supports are sometimes
required to steady an
aircraft.
These supports also known
as Trestles.
Used to prevent unbalance
during maintenance.
Can also be used to support
large components such as
wings and tailplanes.
56
Typical Trestle
Ratcheting
Handle for
Height
Adjustment
Wood beam helps
prevent damage to
aircraft structure
Threaded
rod
57
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.
58
Slinging an Aircraft
Authorised Sling
Crane
59


Any Questions?
60


Flight-Line Safety
61
Flight-Line Safety
A Flight-Line (Ramp) is a dangerous place to work.
Dangers are many:
Tripping over cables and hoses
Hit by air stairs, power sets and catering vehicles
High noise levels so reduced verbal communications
Hit by moving control surfaces and pitot probes
Being sucked into an engine intake
Being burnt or blown over by the engine exhaust
Being hit by a propeller.
62
Normally < 1 m
Flight-Line Safety - Propellers
Accidents involving propellers
are usually always fatal!
63
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.

AMMs show suggested walkways to avoid the danger
areas posed by propellers.
64
100m
75 m
50 m
25 m
0 m
700C
500C
300C
100C
All Values
Approximate.
0 m
20 m
Jet
Aircraft
Danger
Areas
65
Safety when Towing
All operators, aircraft and airports have specific rules
which must be adhered to when towing such as:
Maximum towing speed (Weather dependent).
Minimum turning radius.
Route to be taken to destination.
Airfield radio call sign.
Type of towing vehicle - sufficient tractive effort.
Correct towing arm for that aircraft.
66
Safety when Towing
Towing an aircraft requires the correct number of
trained, qualified and authorised personnel.
Unobstructed communications required between all
team members.
Towing team need the correct PPE such as:

1. High visible jackets.
2. Ear protection.
3. Cold weather clothing.
67
Aircraft Turning Left
Tail Growth
Wing Tip Growth
Swept Wing Tip Growth
68
69
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.
70
Rich, heres one our team did this morning. Tell Carl &
T.O. there lucky they are not the flight chiefs of this
one. Heres 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 yuke 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.
71
72
73
74
75
76
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
77
Come Ahead Stop
(Crossed Hands)
Emergency Stop
Repeat Open & Cross Hands
Standard Marshalling Signals
78
Right Turn
All Clear (OK)
Left Turn
Standard Marshalling Signals
79
Remove Chocks
Slow Down
Insert Chocks
Standard Marshalling Signals
80
Fuelling
Various types of aviation fuels are available for
different aircraft types.

Correct type of fuel is marked adjacent to aircrafts
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.
Continued...
81
Electrical bonding of aircraft and bowser required.

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.
End
82
DISPLAY
OFF MAX
FRZ
LEFT
AUX
SB/T WX WX/T RCT GCR MAP
DISPLAY
OFF MAX
FRZ
RIGHT
ALRT
10 20 40 80 160 320 VAR SEC
TILT
UP
DWN
GAIN
MI N MAX
Weather Radar Safety
83
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.
84
Weather Radar Safety
Testing usually done with
aircraft facing towards open
airfield.
Erect barriers with signs to
warn others when testing
the weather radar.
85
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.
Typical Written Question
86


Any Questions?
End
87