Airport Technology Reports – Aviation Refuelling Solutions – Flofuel

SPECIAL REPORT

Aviation Refuelling Solutions Innovations in Aviation Refuelling Aviation Refuelling: Managing Cashflow A Greener, Leaner Future Improving Safety in Refuelling Future Technologies for Refuelling

Published by Global Business Media

Engine-off refuelling

Safety & operational systems

Tank contents

Maximum vehicle speed

SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

SPECIAL REPORT

Aviation Refuelling Solutions Innovations in Aviation Refuelling Aviation Refuelling: Managing Cashflow

Contents

A Greener, Leaner Future Improving Safety in Refuelling Future Technologies for Refuelling

Foreword

2

Tom Cropper, Editor

Innovations in Aviation Refuelling

3

George Maguire, Group Managing Director of Flofuel Ltd

Challenges in Aviation Refuelling Emissions, Emissions, Emissions Published by Global Business Media

Published by Global Business Media Global Business Media Limited 62 The Street Ashtead Surrey KT21 1AT United Kingdom Switchboard: +44 (0)1737 850 939 Fax: +44 (0)1737 851 952 Email: info@globalbusinessmedia.org Website: www.globalbusinessmedia.org Publisher Kevin Bell Business Development Director Marie-Anne Brooks Editor Tom Cropper Senior Project Manager Steve Banks Advertising Executives Michael McCarthy Abigail Coombes Production Manager Paul Davies For further information visit: www.globalbusinessmedia.org

Fleet Age Staff Development Tied-Up Capital Seasonal Peaks

Aviation Refuelling: Managing Cashflow

6

Tom Cropper, Editor

Rising Demand Barriers to Expansion Investing in Refuelling Financial Challenges Seasonal Budgeting

A Greener, Leaner Future

8

Jo Roth, Staff Writer

The Fight Against Emissions The Impact of Aviation Reducing Refuelling Emissions A Costly Transition

Improving Safety in Refuelling

The opinions and views expressed in the editorial content in this publication are those of the authors alone and do not necessarily represent the views of any organisation with which they may be associated.

James Butler, Staff Writer

Material in advertisements and promotional features may be considered to represent the views of the advertisers and promoters. The views and opinions expressed in this publication do not necessarily express the views of the Publishers or the Editor. While every care has been taken in the preparation of this publication, neither the Publishers nor the Editor are responsible for such opinions and views or for any inaccuracies in the articles.

Issues with Equipment

10

Misfuelling and Fuel Contamination Human Error A Fresh Approach

Future Technologies for Refuelling

12

Tom Cropper, Editor

Electrical Ground Vehicles Digital Revolution

Š 2019. The entire contents of this publication are protected by copyright. Full details are available from the Publishers. All rights reserved.

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Automation and the Cloud

References 14

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SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

Foreword T

here has been considerable technological

them into reverse on a massive scale. Each aspect of

development in refuelling systems over the

the aviation process will have to play its role, including

past few years. However, airports need solutions

refuelling. Fuel efficient vehicles and more efficient

which work within their practical and financial

refuelling can reduce the impact of both ground

constraints and help them meet the crucial

vehicles and aircraft.

challenges coming their way.

As well as improving environmental performance,

As our opening article from Flofuel group states,

the sector must ensure safety. Refuelling is a

this means looking towards innovations which

dangerous business; mistakes here can put

tackle emissions, staff development and capital

everyone’s lives in danger. There’s a risk that, as

requirements. They explain how they are innovating

traffic grows, time pressures will see operators cut

to address these challenges with new technologies,

corners and make mistakes. Now, more than ever,

financing options and training services.

it’s important to use providers who place a strong

Elsewhere, the Report deals with some of these challenges in more detail. First come the finances.

emphasis on safety and go the extra mile to ensure the reliability of systems.

In a world in which capacity is being stretched to

Finally, we’ll look at the innovations shaping

the limit, we’ll see how the pressure is growing on

the future. Electric vehicles, advanced fuels

refuellers to offer value for money as well as an

and digital technology can all transform the

extremely tight turn-around.

landscape. Implementing them effectively will

Next, Jo Roth focuses on the biggest issue of the day: the environment. The world has set itself some

hold the key to many of the biggest challenges facing refuelling operations.

ambitious goals to reduce carbon emissions over the coming years and decades, but unless something can be done about air travel, those targets will be difficult to achieve.

Not only must the industry address recent rises in greenhouse gas emissions, but it needs to throw

Tom Cropper Editor

Tom Cropper has produced articles and reports on various aspects of global business over the past 15 years. He has also worked as a copywriter for some of the largest corporations in the world, including ING, KPMG and the World Wildlife Fund.

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SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

Innovations in Aviation Refuelling George Maguire, Group Managing Director of Flofuel Ltd The engineering and services group for commercial, military and naval aviation refuelling.

Challenges in Aviation Refuelling Much has been written about the transition to filter water separators and other technical advancements in aviation refuelling.

But, what about innovations to address other challenges being faced by airport and aviation refuelling operators such as emissions, fleet age, staff development, tied-up capital and seasonal peaks?

In this article we share how Flofuel is innovating, to solve these and other challenges, not just through technology but also through innovation in services and financing.

Emissions, Emissions, Emissions London’s Heathrow airport, as a part of its Heathrow 2.0 sustainability plan, targets a significant reduction in NOx emissions from airside vehicles. Its 2010 emissions inventory

showed that 9% of ground level NOx emissions were generated by airside vehicles and plant.

Heathrow’s aim is to reduce NOx emissions, from airside vehicles, by at least 50% by 2020 and 70% by 2025 (from a 2013 baseline). As a part of this initiative 100% of airside vehicles will have to meet the latest emissions standards (Euro 6/VI, Stage V, etc.) by the end of 2025.

Heathrow also recently announced that, from 2022, it will extend the capital’s ULEZ (Ultra Low Emissions Zone) to vehicles entering the airport with the aim of keeping the airport free of older and more highly polluting vehicles.

Heathrow is not alone in targeting airside vehicle emissions. Amongst many other airports, Dublin has mandated the use of low-emission vehicles by airside operators by 2022.

Aviation refuelling vehicles spend a significant part of their day parked beside an aircraft, with their engine running during aircraft refuelling.

Currently, one option is to move older vehicles to airports having less stringent emissions requirements, but for how long will this continue to be an option?

FUELTRONICTM ENGINE-OFF REFUELLING

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SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

There’s a way to do it better - find it.

Thomas Edison Inventor

Our FueltronicTM vehicle management system, alongside other benefits, enables the aircraft to be refuelled with the refuelling vehicle’s engine switched off.

One of our customers, operating at a major European hub, reports that Fueltronic’s engineoff capability cut fuel consumption, and related emissions, by over 30%.

Fleet Age Refuelling vehicles have a typical life in excess of 15 years although we have seen vehicles still in operation after 30 years.

With some airports starting to impose a maximum airside vehicle age of 10 years, as a part of their emissions strategy, what options are there to extend refuelling vehicle life?

Currently, one option is to move older vehicles to airports having less stringent emissions requirements, but for how long will this continue to be an option?

To address this growing challenge, we have set up a dedicated facility to re-chassis refuelling vehicles. We can do this for vehicles built by our group companies or by others. Depending upon vehicle age and condition, the re-chassis cost can be as low as 50% of new-build cost. At the same time, we can upgrade the vehicle to current technical and safety standards.

As a further option, again dependent upon vehicle age and condition, we may be able to part-exchange older vehicles against a new vehicle. We then refurbish and rebrand the older vehicle and sell or lease it to smaller airports who may not have sufficient budget for a new vehicle.

Staff Development Staff development plays a vital role, not just 4 | WWW.AIRPORTTECHNOLOGYREPORTS.COM

in upgrading skills and knowledge, but also in building motivation, fostering loyalty and increasing retention.

The latter can be a particular challenge for aviation refuelling operators when there is a wealth of transport-related opportunities beyond the airport perimeter.

To address the limited availability of external training qualifications, for aviation refuelling operatives and supervisors, Flofuel Training developed the BTEC Advanced Diploma in Aviation Fuel Storage and Handling Operations.

This training program, which is backed up by work-based assignments, results in the only internationally recognised formal qualification for aviation refuelling.

Structured in three modules (core, supervisory and management) this course enables refuelling operators to offer ongoing development opportunities to key staff throughout their career.

Tied-Up Capital For larger and smaller businesses alike, cash is king, yet many have considerable sums tied up in their physical assets.

Some of these assets may be of an age where reliability and maintenance costs are becoming an issue, yet cash may simply not be available for an upgrade or replacement program.

To address this challenge, we have worked with financing partners to offer a solution which goes beyond the simple lease of a new refuelling vehicle.

With our partners, we are now able to offer a wrap of existing refuelling vehicles plus other ground support assets, on a sale-leaseback arrangement, together with associated services to upgrade, maintain and support these assets and even train operational staff.

SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

MONTHLY AIR PASSENGER TRAFFIC. Source: Eurostat

Through our vehicle build businesses, Flightline Support and Fluid Transfer International, plus Flofuel Special Projects, Flofuel Support and Flofuel Training, we are uniquely positioned to be able to deliver an assets-as-a-managedservice solution.

vehicle on a litres-delivered basis. This results in lower Opex, and better cashflow, during the quieter winter months, whilst ensuring capacity to manage the summer peak.

If you are facing such challenges, please contact us to discuss options.

Seasonal Peaks Most of us, excluding those fortunate enough to have access to a private jet, have experienced peak summer traffic at the airport. Across the EU28, passenger traffic in the summer months is almost twice that of the winter months. In holiday destinations such as Greece this increases to almost six times.

The result may be a little inconvenience for travellers. For the refuelling operator it can mean having to keep additional vehicles on the balance sheet, less used for up to six months of the year, to manage the summer peak.

To address this challenge, we are working with our financing partners to launch a further extension of our asset-as-a-managedservice solution.

One variant is for the operator to pay, under Opex instead of Capex, for use of the refuelling

Contact

Most of us, excluding those fortunate enough to have access to a private jet, have

+44 (0) 1993 222540 enquiries@flofuel-group.co.uk flofuel-group.co.uk Visit us at inter airport Europe 2019 Hall B6 - Stands 340 and 359

experienced peak summer traffic at the airport

Munich Trade Fair, Germany 8-11 October 2019

Aviation refuelling vehicles spend a significant part of their day parked beside an aircraft, with their engine running during aircraft refuelling

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SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

Aviation Refuelling: Managing Cashflow Tom Cropper, Editor The aviation industry is focusing on three things: how it can satisfy demand while reducing carbon emissions and staying profitable. Each makes the other more difficult.

I Expansion is expensive, time consuming and controversial. As Heathrow’s current plans for a new runway demonstrate, construction and expansion projects regularly run into political and financial barriers

T’S A curious feature of aviation that, at a time when more people are expecting to fly than ever before, this still feels like a sector which is under fire. Demand may be rising, but at the same time, it is becoming more difficult to maintain profits. Airports have to manage a difficult juggling act of reducing costs while finding a way to cater for all the people who want to fly. Every penny counts and the point at which aircraft are refuelled is becoming critical.

The challenge is two-fold. Firstly, they have to move quickly to turn around aircraft in the shortest possible time to increase the hours they spend in the air generating revenue. Secondly, with the cost of fuel rising, they must do this in the most financially sustainable way possible.

Rising Demand The first challenge is tough enough. IATA’s longterm passenger forecast predicts more than 8 billion passengers by 2037, double the number today1. Growth will be fuelled by a boom in air travel from developing economies such as China, but demand is expected to rise steadily in more established markets such as Europe and the US. Airports will increasingly find themselves operating at or near capacity. Airbus and Boeing both report that the number of aircraft in use could double over the next 20 years. IATA warns that hundreds of airports could hit capacity over the next ten years. There is, they say, a ‘significant gap’ between available capacity and demand2.

Already there are 189 airports which are declared full around the world with 21 one of them being in China, and the number of slots for aircraft is still growing. Slot coordination and airport capacity will be prevailing issues in the future.

Barriers to Expansion The obvious solution is to build more airports or expand the ones we have and this is happening.

Airport construction is a growing industry with the US alone spending more than $70bn on 50 airport 6 | WWW.AIRPORTTECHNOLOGYREPORTS.COM

construction projects3. According to market data, the overall value of the global airport construction market currently stands at US$737.3 billion, of which US$212.0 billion is in the planning stage.

Asia-Pacific accounts for the highest value with US$241.4, as it tries to alleviate its growing airport congestion problems4.

However, expansion is expensive, time consuming and controversial. As Heathrow’s current plans for a new runway demonstrate, construction and expansion projects regularly run into political and financial barriers. Many airports simply do not have scope to expand without causing unacceptable damage to the surrounding communities.

Expansion and construction alone, therefore, will not solve the problem. Airports will have to become much more efficient and expand the number of slots available. This places pressure on every aspect of operations from security and check-in processes in the terminal to airside operations such as refuelling.

Investing in Refuelling All of this creates a fertile environment for growth within the refuelling industry as airports look to upgrade their infrastructure to cope with growing demand and develop more financially efficient operations.

A report from TMR predicts the market to grow at 4.8% year on year between 2017 and 2025 by which time it will be worth US$12,868.7 million.

This is up from its estimate of US$8,146.0 million back in 20155.

New technologies are more efficient, reduce the risks of fuel contamination, have faster turnaround times as well as lower fuel consumption and emissions. They help airports meet their financial, capacity and environmental goals, but there is a predictable catch – money.

Financial Challenges Many airports, especially smaller and medium sized hubs, will face challenges of capital. They

SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

want to develop infrastructure, but financial realities are stopping them from doing so.

The situation is muddied by fluctuating energy markets. As the price of diesel rises, fuel usage becomes an increasing priority. New refuelling vehicles offer greater fuel efficiency with some electric vehicles giving the prospect of cutting out fuel for ground operations altogether, something which helps both financial and environmental goals.

Less expensive alternatives such as adjusting existing vehicles so that they can become more fuel efficient represent a more affordable option, but this will be a recurring issue. Operators will have to make careful calculations to decide if they can afford an innovation and how quickly they will see a return on their investment.

Seasonal Budgeting Tight budgets make it difficult to deal with seasonal peaks and troughs. Airport staff shortages are a common feature of the summer season as airports struggle to deal with increased passenger and aircraft numbers.

Every department comes under pressure. With schedules becoming tightly packed, ground crews will need to be operating at peak efficiency.

Where staff and equipment levels are stretched,

delays become almost unavoidable. It only takes a small holdup because of vehicle unavailability or a problem with paperwork to create a ripple effect across the entire schedule.

The result is an increased risk of error as teams scramble to meet tight deadlines, angry customers and lost revenue.

Airports will benefit from increasing vehicle and personnel during peak times, but this requires a capital investment, which may be difficult to find.

Some manufacturers have recognised this and adopted flexible pricing or rental options to help airports temporarily build infrastructure capacity in a financially sustainable way. This can benefit both sides, by help airports innovate and securing more business for manufacturers.

Innovation, then, can help aviation meet its financial challenges, but there may need to be some imaginative solutions from all sides to make innovation financially sustainable. Airports are certainly being confronted with a tough ask.

On the one hand they need to invest more to handle increased passenger numbers. On the other, they have to do this with more limited funds.

The phrase ‘doing more with less’ often gets bandied about, but this is what airports are being asked to do. To meet that goal, next generation technologies will be crucial.

Some manufacturers have recognised this and adopted flexible pricing or rental options to help airports temporarily build infrastructure capacity in a financially sustainable way. This can benefit both sides, by help airports innovate and securing more business for manufacturers

Every department comes under pressure.

With schedules becoming tightly packed, ground crews will need to be operating at peak efficiency.

Where staff and equipment levels are stretched, delays become almost unavoidable

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SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

A Greener, Leaner Future Jo Roth, Staff Writer The aviation industry faces an enormous challenge of satisfying growing demand while meeting tough carbon reduction targets.

T

Science can so often be cautious in its statements, but this was remarkably blunt. Governments, it said, had 12 years to limit climate change catastrophe

HE FIGHT against climate change is the biggest challenge facing the world and it’s one in which the aviation industry is on the front line. As one of the largest contributors to carbon emissions, it is in a position to generate substantial reductions in emissions. However, as demand increases, it also has to manage more passengers and more flights. It’s a circle in need of being squared, so how can they manage it?

The Fight Against Emissions In years to come, 2018’s Intergovernmental Panel on Climate Change (IPCC) report on Climate Change may come to be seen as a watershed moment. Science can so often be cautious in its statements, but this was remarkably blunt.

Governments, it said, had 12 years to limit climate change catastrophe6.

If a rise in global temperatures is to be restricted to 1.5 degrees, emissions will need to be cut by 45% by 2030 and the world will need to move towards zero net carbon emissions by 2050. It was the kind of stark deadline which concentrates minds and it has worked. What followed was Greta Thunberg, the school climate strikes and Extinction Rebellion. Governments took action and, in one of her final acts as Prime Minister, Theresa May committed the UK to net zero carbon emissions by 2050.

Suddenly, climate change has hit the front pages. Campaigners who have been hammering at the door for years must feel as if it has suddenly been flung open causing them all to crash through onto the other side. However, if these targets are to be achieved, something has to be done about aviation.

The Impact of Aviation As a paper on climate change from the European Union states, aviation is the fastest growing source of greenhouse gases. Aviation accounts for 3% of the EU’s total emissions and 2% of the world’s. If it were a country it would be in the top ten polluters and a single person travelling from London to New York and back generates as many emissions as the average person heating their house for a year7.

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That figure is rising. Data from IATA finds that annual emissions from the aviation sector is approaching the billion-tonne mark. Total emissions were 860 million tonnes in 2017; 905 million tonnes in 2018; are expected to be 927 million tonnes in 2019. If IATA’s own projections of a 100% increase in passenger numbers within the next two decades are correct, the impact would render all other attempts to fight climate change obsolete8.

In years gone by, data such as this would have been greeted with a shrug, but it’s an increasing PR and business problem for aviation. Flight shame is a growing phenomenon with more and more people giving up flying in favour of slower, but cleaner forms of travel.

Ten of the Swedish state-owned airports, for example, experienced a 3% fall in passengers as more and more people chose to give up flying. Organisations such as Flight Free UK have successfully encouraged thousands of people to give up their addiction to air travel9. Some radical ideas suggest rationing the number of flights each person could take every year. These could be traded between individuals limiting total flight numbers each year10.

This is a very real business issue for the sector.

Consumers demand it and so do economic realities. Fuel costs are rising and managing these will become a growing challenge in the years to come. So, from a moral, environmental and financial perspective, the industry needs to make progress quickly.

Official targets show the scale of the challenge.

The EU has set targets for the industry to cut CO2 emissions by 75%, nitrogen oxides by 90% and noise pollution by 65%11. For a sector which is focused on expansion, this is a massive challenge, but it’s one that it must embrace.

To achieve it, airports will need to take an organisation-wide approach which takes almost every aspect of operations into consideration.

Reducing Refuelling Emissions Refuelling can have a significant impact.

Firstly, the sector needs to control its use of fuel. Over- fuelling will lead to excessive fuel consumption, while contamination or errors in

SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

FLOFUEL GROUP’S REFURBISH AND RE-CHASSIS FACILITY

refuelling could force aircraft to return to their origin, defuel and refuel to go again.

Refuelling operations which can show high levels of accuracy and reliability, therefore, can lead to incremental improvements in fuel efficiency. Operators will also have to look at how they use fuel in their ground operations.

Fuel consumption is a growing issue. Newer refuelling vehicles come equipped with more efficient engines as well as the ability to refuel while the engine is off. With each airport managing thousands of refuelling operations each month, small gains here add up to major gains over the course of a year.

Modern vehicles also have much more efficient engines. The latest models conform to Euro 6 emissions standards and can come with hybrid engines which use a combination of petrol and electric engines to power the vehicles.

Some airports have even moved towards fully electric vehicles.

In years gone by, data A Costly Transition

such as this would

However, the transition can be costly and cumbersome. Refuelling vehicles have a life expectancy of around 15 years and, if an airport has older vehicles, replacing these can be financially unsustainable. Some providers, therefore, offer services which allow the upgrading of existing vehicles so that their emissions are reduced, and they operate in a cleaner way.

There is no one single magic change which can help the aviation industry make the transition. However, emissions will be a growing issue in the years to come. Consumers have demonstrated a willingness to act with their wallets and authorities are setting increasingly ambitious targets. It requires wholesale change across the spectrum to make significant reductions throughout all operations. It will be difficult but it is possible if suppliers, airports and airlines work together.

have been greeted with a shrug, but it’s an increasing PR and business problem for aviation. Flight shame is a growing phenomenon with more and more people giving up flying in favour of slower, but cleaner forms of travel

Aviation accounts for 3% of the EU’s total emissions and 2% of the world’s. If it were a country it would be in the top ten polluters and a single person travelling from London to New York and back generates as many emissions as the average person heating their house for a year

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SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

Improving Safety in Refuelling James Butler, Staff Writer Safety has to be the number one consideration for refuelling and, although there has been progress, incidents are still too frequent.

T

Fuelling issues are one of the most serious threats to aircraft. If water is ingested into the system, it can settle at the bottom of the tank and affect the function of the engines. During cold weather, it can freeze, blocking the fuel system or causing ice crystals to form

HE AVIATION industry has worked hard over the years, to improve the safety of its operations. Even so, accidents still happen.

Refuelling remains a risky business and, as the pressure rises to improve turnaround times, there is a danger that errors will become more common.

Airports will all have their own refuelling strategies, each of which present different challenges and risks. Smaller gateways will rely on refuelling trucks which carry the fuel directly to the airport, while larger hubs tend to have their own onsite fuel dumps and underground hydrant refuelling systems.

Each approach has its own benefits and pitfalls. Risks come from many sources, from fires on the ground to fuel contamination or misfuelling errors. Each airport will have to assess the specific risks and develop its own approach to safety.

Misfuelling and Fuel Contamination Fuelling issues are one of the most serious threats to aircraft. If water is ingested into the system, it can settle at the bottom of the tank and affect the function of the engines. During cold weather, it can freeze, blocking the fuel system or causing ice crystals to form.

Salt-water contamination can also affect the function of engines. In 2010, a Cathay Pacific flight, arriving at Hong Kong International from Surabaya Airport, experienced problems controlling thrust. One engine became unusable and the crew performed a safe emergency landing at excessive speed, sparking alerts of a fire in the landing gear. Investigations identified salt-water contamination in the hydrant refuelling system as the cause of the problem12.

Miscalculations of the amount of fuel delivered can happen. Administrative errors on the ground can lead to the wrong truck attaching to the wrong aircraft and delivering the wrong type of fuel. In some cases, fuel readings may not be entirely reliable.

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In 2014, a flight to Singapore experienced discrepancies between the fuel remaining figure derived from fuel used assuming that departure fuel had been as indicated, and the figure produced from directly measuring the fuel in the tank. As soon as the discrepancy was noted, the aircraft returned to its origin where it was discovered that there had been a fuel overload.

Flight crew had requested a fuel uplift to 86 tonnes, but, although this figure was shown on the aircraft refuelling panel and, in the flight deck, a check of the fuel loads at the fuel flow counter came back as 121.5 tonnes. The dispenser was uncertain if he had reset the flow counter, but accepted the suggestion of the certifying technical personnel that the counter might not have been reset prior to refuelling, even though he later told investigators that fuelling would not have been allowed if the counter had not been reset13. Despite the findings of the test, the incorrect figure was accepted and the aircraft allowed to depart.

Human Error For all the improvements manufacturers can make to technology and equipment, human error remains the biggest risk. In 2001, a fire broke out when a BA jet was being refuelled.

During the refuelling process, the inboard fuelling hose suddenly separated from the aircraft and began flapping around and spraying fuel. It ignited and engulfed the area in flames.

Fire trucks arrived within minutes and extinguished the fire immediately, but the refueller suffered fatal injuries.

According to the investigation, the airplane’s refuelling adapter suffered an overstress fracture due to an abnormal angular force being applied after the refueller incorrectly positioned the hydrant fuel truck, and his inattentiveness while lowering the refuelling lift platform14.

It’s a good example of the kind of problem which could have been avoided with better training and oversight.

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BTEC STUDENTS AT FLOFUEL TRAINING

Issues with Equipment Refuelling manufacturers are constantly looking to improve their products and address any unforeseen issues which can arise with their equipment. For example, materials in some filters can migrate into the aircraft causing problems within the fuelling system.

Extensive testing will be required to identify any potential problems so that manufacturers can rectify them before they spark an incident. The more comprehensive the testing procedures and the more they can mimic real-world situations, the more reliable equipment will be. Accordingly, when choosing providers, it is worth assessing their testing facilities and processes to assess how reliable equipment will be when operating under different conditions.

A Fresh Approach There are gaps in refuelling processes which could be addressed with a more comprehensive approach. Flofuel group has argued for what it describes as a ‘360-degree approach’ to safety.

They argue that safety must be a top-down process in which every stakeholder, from senior managers to ground personnel, is actively involved. This incorporates extensive testing, product development and personnel training to create an all-encompassing safety strategy. As part of this, they’ve partnered with Shell to make modifications to their fuel farm including new testing technologies to safeguard against water slugs and contamination in the fuel supply. By

Right from the top to the injecting water into fuel at the test site, they can better understand how equipment reacts in real world conditions.

They also offer a fuel testing facility for fuel filter manufacturers to improve the performance of fuel filters. A test vehicle simulates the effects of materials within the filters getting into the aircraft.

This helps manufacturers to understand the true performance of the products they supply and where they need to be improved.

Training is a core ingredient. The company has become a key training provider with an independently verified BTEC course aligned to the European Aviation Safety Agency and the Energy Institute requirements. This provides customers with an independently accredited qualification to ensure organisations and staff adhere to the highest safety standards.

“Our approach is total 360 degrees,” states a Director of Flofuel Support Ltd. “Right from the top to the bottom, everyone is involved and everyone is responsible. And we take that approach very seriously15.”

Safety must be an ongoing process incorporating equipment testing, personnel training and risk assessments to improve the safe operation of equipment. All stakeholders, from manufacturers to airport operators and ground crew must enhance their understanding of how systems operate, the potential dangers and how to mitigate them. The results will be a safer working environment for personnel, aircraft and passengers.

bottom, everyone is involved and everyone is responsible. And we take that approach very seriously

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Future Technologies for Refuelling Tom Cropper, Editor Digital technology, electrical vehicles and even airborne refuelling can all contribute to a safer, greener and more efficient future.

A Rapid progress in battery technology is starting to enable all-electric refuelling vehicles to become more commercially viable and is raising the interest in all-electric refuelling, with airport and refuelling operators alike

S WE’VE seen so far in this Report, the aviation sector has some serious questions to answer in the future. How does it reduce turnaround times to increase capacity? Can it reduce carbon emissions while satisfying increased demand and how can it reduce operating expenses to ensure financial sustainability? The answer to all of these questions may lie in new technologies.

In this final article, we’ll look at some of the technical innovations which could shape the future of refuelling.

Electrical Ground Vehicles The most difficult challenge could be environmental. Airports are under pressure to deliver dramatic reductions in the production of greenhouse gasses. To do so, they will need every part of their operations to contribute.

The fuel used by ground vehicles contributes significantly to both operating costs and the overall carbon footprint. Having internal combustion engines close to aircraft refuelling operations also creates a health hazard, so it’s no surprise that airports are turning their attention to vehicles which reduce or eliminate petrol use.

Back in 2009, Fluid Transfer International which is now a part of the Flofuel group of companies, launched the first all-electric hydrant dispenser which was operated at Stansted airport.

Fluid Transfer’s RAZER and Tesla’s Roadster, which was launched the previous year, faced similar challenges in terms of battery capacity, longevity and cost. This limited the commercial success of both vehicles.

The past couple of years have seen rapid progress in battery technology both in terms of energy density and cost. This is starting to enable all-electric refuelling vehicles to become more commercially viable.

This, alongside emissions initiatives already in place at many airports around the globe, is raising the interest in all-electric refuelling vehicles, with airport and refuelling operators alike.

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Digital Revolution Innovations like this typify the ongoing automation and digitisation of refuelling operations. ‘Digital transformation’ is a phrase which is commonly heard across all business sectors, and aviation is no different. By digital transformation we mean the process of completely embedding digital into the very DNA of an operation rather than solving individual problems with single innovations.

In this world, data is fluid and transferrable and can be instantly accessed remotely by multiple operators. In an admin-heavy process such as refuelling, that can be an enormous bonus as it helps to streamline processes and reduce delays.

Operators will have become accustomed to the laborious process of manually completing all the necessary documentation. By using handheld tablets in robust explosion proof casings, they can make all the entries in real time.

Vehicles can use displays and GSM units with printers to create documents, take fuel quality measurements and transmit all the necessary information back to a central location. Digital sensors inside fuel tanks can give more information on factors such as fuel density, mass and flow giving operators greater oversight about the quality of the fuel being added into the aircraft.

Automation and the Cloud By automating processes, operators can reduce the time taken for administration and the risks of schedules being delayed while crew are waiting for the right documents to be completed. Prompt alerts are issued if there is a problem with the fuel and the amount of overall information at the disposal of operators is increased. This can be used to derive insights and draw learnings which enable processes to improve further.

As digital technology permeates every part of the refuelling process, it will generate enormous amounts of data; and the more data that is collected, the bigger the role data analytics will have. Airports will be increasingly focusing on how they can harness the power of data

SPECIAL REPORT: AVIATION REFUELLING SOLUTIONS

FLUID TRANSFER FT RAZER AT STANSTED IN 2009

analytics to further improve operations and identify potential gains.

Digital technology can also be used to further reduce the risk of misfuelling. Better training and support can improve the capacity of ground crews and reduce mistakes, but there will always be a risk. Technology can step in to compensate for any human errors.

BP’s cloud-based airfield automation platform is being installed in its first airports and claims to be the first to create an engineering barrier to misfuelling16. It consolidates data into its Safe2Go app which can be accessed via a handheld device. This captures fuel volume readings and checks on fuel before electronically recording customer details confirmed by an electrical signature either by the pilot or an official from the airline. This, says the company, creates an

additional barrier to misfuelling, minimises the risks of errors and offers more accurate and detailed data to customers.

Innovation can be found everywhere and is delivering a host of improvements. Greener engines reduce the cost of fuel and carbon footprints. Data analytics enables companies to create real time information and streamline operations; and advanced fuels can reduce costs and improve the environmental performance of the entire industry. At the same time, support and training services will become more valuable as airports seek to minimise errors and maximise productivity of their ground crew. Manufacturers who can provide a blend of these innovations will offer considerably more value than those who are labouring to catch up.

Digital technology can also be used to further reduce

Operation of Fluid Transfer’s FT Razer is simple. Users can simply shift it into forward or reverse and it can be recharged overnight to take advantage of offpeak electricity. As the cost of diesel rises, this becomes an increasingly attractive proposition

the risk of misfuelling. Better training and support can improve the capacity of ground crews and reduce mistakes, but there will always be a risk. Technology can step in to compensate for any human errors

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References: 1

IATA’s Long Term Passenger Forecast: https://www.iata.org/pressroom/pr/Pages/2018-10-24-02.aspx

2

IATA: Hundreds of Airports Hit Capacity: https://www.joc.com/air-cargo/iata-hundreds-airports-hit-capacity-airline-market-grows_20171207.html

3

Why Building New Airports Like Salt Lake City is Rare: http://bit.ly/2kfzBCF

Project Insights Global Airport Construction Market: https://www.premiummarketinsights.com/reports-gd/project-insight-global-airport-construction-projects

4

Aviation Refuelling Market in 2025: https://www.globenewswire.com/news-release/2018/02/20/1361865/0/en/Refueling-Aircraft-Market-to-be-worth-US-12-868-7-mn-by-2025-TMR.html

5

We Have 12 Years to Limit Climate Change Catastrophe: https://www.theguardian.com/environment/2018/oct/08/global-warming-must-not-exceed-15c-warns-landmark-un-report 6

7

Reducing Emissions from Aviation: https://ec.europa.eu/clima/policies/transport/aviation_en

8 IATA CO2 Emissions Approaching a Billion Tonnes: http://www.airportwatch.org.uk/2019/06/iata-aviation-co2-emissions-in-2018-approaching-1-billion-tonnes/

Flight Shame: Airlines are Under Pressure to Cut their Emissions: https://www.latimes.com/business/story/2019-08-27/flight-shame-can-airlines-ever-reduce-their-emissions

9

People Should Limit Themselves to One Flight a Year: https://inews.co.uk/news/politics/britons-should-limit-themselves-to-one-flight-a-year-says-green-party-leader/

10

11

European Environment Report: https://ec.europa.eu/transport/sites/transport/files/2019-aviation-environmental-report.pdf

12

A333 Hong Kong Accident Report: https://www.skybrary.aero/index.php/A333,_Hong_Kong_China,_2010

13

B772 En-route to Northern Indian Ocean: https://www.skybrary.aero/index.php/B772,_en-route,_northern_Indian_Ocean,_2014

14

Incident Report British Airways Boeing 777 Flight 2019: https://aviation-safety.net/database/record.php?id=20010905-1

15

16

FloFuel Group: Our Approach to Safety: http://www.flofuel-group.co.uk/our-approach-to-safety New Digital Platform for Safe Aircraft Refuelling: https://www.mro-network.com/airport-equipment-services/new-digital-platform-safer-aircraft-fueling

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Notes:

Maximum vehicle speed

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Notes:

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