Refuelling with passengers

Refuelling with Passengers on Board

Refuelling an aircraft with passengers still or already on board carries an elevated fire risk — fuel vapour, static electricity, and potential ignition sources are critical.

Source: ICAO Annex 6 Part II; EASA Easy Access Rules for Part-NCO (general PIC responsibility); for commercial EASA CAT.OP.MPA.195 (Refuelling/defuelling with passengers).

Risk

Avgas (100LL) is a highly flammable Class 3 dangerous good:

• Flash point ~−43 °C — vapour ignites at normal outdoor temperatures.
• Lower explosive limit (LEL): 1.4 %.
• Upper explosive limit (UEL): 7.6 %.

Jet A-1 less volatile (flash point ~+38 °C), but still explosive under prolonged exposure.

Ignition sources:

• Static electricity (pump, hose, person disembarking).
• Electrical loads (engine, avionics, mobile devices).
• Mechanical sparks (tools, zip fasteners).

Basic rules during refuelling — the three duties

During the refuelling process three elementary rules must be observed:

1. No open fires in the immediate refuelling area — no welding, no open flames, no matches/lighters.
2. No smoking — no smoking by the pilot, ground personnel, or passengers in the entire refuelling zone (typical 15-50 m safety perimeter).
3. Attach grounding cables — the aircraft is electrically grounded and bonded conductively to the fuel truck / tank ("bonding"), so that static electricity cannot build up from the fuel flow. Static electricity is a classic ignition source for fuel vapour.

These three points are in the standard refuelling procedure at every airfield (ground-crew check) and must be verified by the pilot.

Best practice for general aviation (NCO)

Recommended rule: refuel ONLY without passengers on board.

If unavoidable (tight schedule, weather, emergency):

1. Engines OFF, all electrical loads OFF (avionics master, strobes, beacon).
2. Smoking OFF (obvious, but stated).
3. Passengers briefed and belted in — ready for immediate evacuation.
4. Doors UNLATCHED (for fast egress).
5. Fire extinguisher ready (on board or at the refuelling station).
6. Grounding of the fuel line at the aircraft (against static charge) — standard procedure at the pump.
7. Refueller (person) communicates with the pilot on procedure.
8. Pilot stays at the cockpit or near the pilot door to react quickly.
9. No mobile devices in the immediate refuelling area.

Who is responsible?

The Pilot in Command (PIC, NCO.GEN.105) carries the final responsibility. The airfield refuelling service has its own procedures that apply in addition.

Commercial operations — CAT.OP.MPA.195 (comparison)

For commercial flights (transport, charter), refuelling with passengers on board is strictly regulated:

• Cabin crew present (for evacuation control).
• Doors and emergency exits clear.
• Lighting on for possible evacuation.
• Communication established between cockpit and cabin crew.
• NOT PERMITTED: refuelling with jet fuel with pax on board when flash point is exceeded (e.g. hot days).

In NCO there is no cabin crew → the pilot takes this role.

Fire during refuelling

1. Stop refuelling immediately (inform refueller).
2. Engines stay off (do not start).
3. Immediate evacuation of all passengers — through the nearest door.
4. Move away from the aircraft (at least 50 m).
5. Alert the fire brigade.
6. Pilot leaves last — verifies empty cabin.

Fire fighting at the aircraft

• CO₂ or Halon extinguishers: suitable for fuel fires.
• Water: not recommended (splash hazard, spreads fuel).
• Foam: often available at the refuelling station — best for large fuel fires.