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Ensuring Safe Aircraft Refuelling: A Guide to Prevent Fuel Incidents. Safe aircraft refuelling remains one of the most critical ground handling operations in aviation. Every litre of jet fuel transferred represents both energy and potential hazard—requiring strict adherence to procedures that ensure the protection of personnel, aircraft, and the environment. The recent American Airlines fuel leak incident, in which a ground worker reportedly lost control of a refuelling hose, dramatically underscored the importance of vigilance and proper technique. The video, widely circulated online, showed uncontrolled fuel spray across the apron, a stark reminder that even momentary lapses in procedure can escalate into costly and dangerous events.
Such incidents reinforce the aviation industry’s collective responsibility to uphold HSSE (Health, Safety, Security, and Environment) standards at every operational stage. From hose inspection to the proper use of the deadman control, safety is not just procedural—it is cultural. This article outlines industry-approved refuelling procedures, identifies common pitfalls, and shares expert insights into how training, regulation, and emerging technologies are strengthening safety and preventing future fuel incidents in ground handling operations.
Overview of Refuelling Procedures
Aircraft refuelling is a systematic operation governed by internationally recognized standards such as JIG 1, EI 1540, and NFPA 407. Before any fuel is transferred, pre-refuelling checks must be completed to verify the integrity of both the equipment and aircraft interfaces, including establishing safety zones and measures to prevent static discharge.
Pre-Operation Checks
Operators conduct a visual inspection of hoses, couplings, swivels, and nozzles to detect cracks, leaks, or signs of wear. The aircraft adaptor must be confirmed free of damage, missing lugs, or contamination. Any defect must be escalated immediately to the airline representative. Proper connection of bonding cables is essential to mitigate the risk of static electricity buildup during fuel transfer.
Equipment Readiness
Each vehicle must be fitted with a functioning Emergency Fuel Shut-Off (EFSO) on both sides and, if applicable, on elevating platforms. The deadman control system, a mandatory safety feature, ensures fuel flow continues only while the operator actively maintains pressure on the handheld switch. This system must stop fuel flow within 5% of the current flow rate when released. Jamming or overriding the deadman switch is a serious violation of safety protocols. Regular pressure monitoring and maintenance of filtration systems are crucial for equipment reliability.
Operational Flow
Refuelling begins only after all grounding, bonding, and communication protocols are in place. The operator continuously monitors fuel pressure, nozzle security, and communication with the flight crew. Hydrant dispensers and overwing refueling methods each require specific safety considerations. Should an abnormal condition arise—such as a sudden loss of pressure or visible leakage—the operator must immediately release the deadman control, activating automatic shutdown and minimizing spill potential.
Post-Refuelling Procedures
Once fuelling is complete, nozzles and couplers are checked again for leaks or damage, hoses are rewound correctly, and never drag couplings on the ground. Routine maintenance and testing—such as hose pressure tests and nozzle wear gauge checks—ensure ongoing compliance and reliability. Quality control procedures are implemented to maintain the integrity of the fuel and equipment.
Common Pitfalls and Recommendations
Despite robust procedures, refuelling errors still occur—often due to human factors or equipment neglect. The most frequent pitfalls include:
- Bypassing or jamming the deadman control, preventing automatic shutdown.
- Neglecting daily inspections, leading to cracked hoses, loose couplers, or degraded seals.
- Improper personal protective equipment (PPE) usage, increasing risk of fuel exposure or eye injury.
- Failure to verify the aircraft adaptor condition, resulting in poor nozzle engagement and potential disconnection under pressure.
- Continuing fuelling with known system faults, such as inoperative EFSO or worn nozzles.
To mitigate these risks, organizations must cultivate a safety-first culture supported by continuous training and audits. Key recommendations include:
- Strict Adherence to PPE Policies – Minimum protective gear should include flame-resistant clothing, gloves, non-slip footwear, bump caps, hearing protection, and high-visibility clothing. Safety goggles are essential during sampling and nozzle connection.
- Regular Functional Testing – Deadman controls, pressure regulators, and EFSO systems must be tested to ensure shutdown within the specified flow-rate margin.
- Competency-Based Training – Personnel must be trained not only in procedure but also in the reasoning behind safety systems, such as why wedging a deadman control compromises the entire HSSE framework.
- Reporting and Maintenance Discipline – All leaks, coupling slippage, or worn adaptors must be documented and corrected before the next operation.
- Emergency Preparedness – Ensure all personnel are familiar with the location and use of fire extinguishers, spill kits, and emergency procedures.
As one industry expert commented on LinkedIn following the American Airlines incident:
“Do not bypass the deadman—this airport will likely re-train every fueler after this video.”
Such comments underscore that safety failures are rarely due to technical complexity—they stem from complacency, poor supervision, or pressure to rush operations. A single procedural lapse can cascade into environmental damage, flight delays, and reputational loss.
Industry Standards and Regulations
Aircraft refuelling operations are governed by an integrated network of international standards that establish uniform safety benchmarks:
- NFPA 407: Specifies equipment requirements for deadman systems, emergency shut-offs, and fuel-flow controls.
- JIG 1 & EI 1540: Define best practices for fuelling operations, maintenance intervals, and inspection regimes.
- FAA Advisory Circular 150/5230-4C and EASA Part 145: Establish the regulatory basis for maintenance training, personnel competence, and fuel-handling quality assurance.
These frameworks ensure operators adhere to principles of redundancy, traceability, and control—where no single point of failure can cause a major incident. They also align with local environmental protection regulations, requiring prompt containment and reporting of spills.
Airports and into-plane service providers must demonstrate compliance through periodic audits, calibration records, and operator certification. In addition, digital tools such as Computerized Maintenance Management Systems (CMMS) are increasingly used to track interventions, schedule inspections, and flag anomalies before they become risks.
Insights from Industry Professionals
Ensuring Safe Aircraft Refuelling: A Guide to Prevent Fuel Incidents
Following the American Airlines leak, the aviation community engaged in open discussion about refueling discipline and safety accountability. Experienced professionals highlighted that while technology supports safety, human vigilance remains irreplaceable.
“The fueler lost control of the hose because the system’s fail-safes were either bypassed or malfunctioning. Training must focus on instinctive safety responses—not just checklist compliance.”
Meanwhile, ARC NV’s and Group CéSAR’s “Weekly Aviation Fuel Quiz” campaign emphasized knowledge retention through interactive awareness, engaging operators worldwide to refresh their understanding of standards.
“Knowledge and repetition build habits. Every question we answer correctly in training could be the mistake we prevent on the apron,” one ARC trainer remarked.
Industry discussions have also pointed to innovations enhancing safety, including:
- Smart deadman systems with automatic timeout resets and feedback indicators.
- Digital inspection reporting platforms integrating image-based verification of hoses and couplers.
- Predictive maintenance analytics, identifying wear trends before failure.
- Automated systems for fuel quality control and monitoring.
- Specialized equipment designed to enhance safety in various refueling scenarios.
Collectively, these developments show a clear trend toward data-driven HSSE management, supported by real-time monitoring and shared best practices. However, experts agree that technology must augment, not replace, operator awareness.
Conclusion
The American Airlines fuel leak serves as a powerful reminder that aircraft refuelling safety is a shared responsibility—spanning manufacturers, operators, and supervisors alike. Every hose, coupling, and control system represents a link in a chain, where a single weak point can trigger a cascading failure. Adherence to correct procedures, continual inspection, and use of the deadman control as designed are not optional—they are lifesaving measures.
Aviation fuels are unforgiving of error. Whether on a regional ramp or an international hub, preventing fuel spills and leaks requires unwavering professionalism, robust training, and full alignment with international standards. The industry’s mission is clear: zero tolerance for procedural shortcuts and zero incidents in refuelling safety.
Call to Action
To reduce the likelihood of incidents, consider the following recommendations:
- Regular Training: Continuous training for all personnel involved in refuelling operations is essential. This training should cover safety protocols, equipment handling, and emergency procedures.
- Routine Equipment Maintenance: Implement a regular maintenance schedule for all refuelling equipment. This includes inspections for wear and tear, as well as testing safety features like the deadman control.
- Adherence to Aviation Safety Protocols: Strictly follow established guidelines for aircraft refueling hazards and safety measures.
Aviation professionals are urged to re-commit to safety training, peer review, and procedural discipline. Share lessons learned, participate in refresher programs, and uphold the highest HSSE values. Every operator on the ramp plays a role in maintaining fuel safety excellence—because when procedures are followed, incidents like this one never happen. ✈️💧
