IOGP high potential event report

Incident description:

On 07th of February 2018, a technician was planning to drain a generator pump in preparation for transport. This was completed inside the bund where a drum used to decant Jet-A1 waste fuel drum was located. The waste drum contained recently tested fuel samples. Just after midday on the same day, a loadmaster and three assistants went to the refuelling area to refuel two BK117 helicopters (Helo 1 and Helo 2) with Jet-A1 drum fuel. Helo 1 was refuelled first followed by Helo 2. After refuelling, both helicopters departed for their respective work locations. Approximately 15 minutes after departure, one of the personnel involved in draining the generator pump in the bund returned to the fuel area and realised that the Jet-A1 waste fuel drum had been utilized to refuel the helicopters. He immediately alerted the other helicopter company loadmaster, who then informed the site Dispatcher. Helo 1 was heading back to a seismic location and was advised by the Dispatcher to land and shut down at the location's Pad 1. The Dispatcher relayed the message to the Lead Pilot via the radio. The Dispatcher then contacted Helo 2 and advised the pilot to land and shut down at another helipad. Helo 2 landed safely. A helicopter engineer attended and inspected the helicopter. There was no evidence of contamination. Helo 2 was approved to return to service. At the seismic location main base, the refuelling pump filter was removed, checked for contamination and declared clear of contamination. A helicopter engineer from the contractor organisation checked Helo 1 and there was no evidence of contamination. Helo 1 was approved to return to service

What Went Wrong:

Drum refuelling was an inappropriate method of refuelling compared to drum refuelling due to higher risk of fuel contamination and human error. Helicopter Loadmasters inadvertently fuelled 2 helicopters from a waste fuel drum The fuel arrangements within the Aviation Task Plan for project did prescribe use of bulk fuel, not drum fuel. Drum fuel was only to be used for initial activities and not for longer term use. The use of drums in the interim period was not assessed for appropriate manning levels against planned flying hours. Fuel drums and waste drums were not adequately labelled to prevent mis-identification. Waste drums and fuel drums were not adequately segregated.

Corrective Actions:

Drum refuelling is only recommended for short duration or light usage - bulk refuelling systems should be used to reduce likelihood of contamination and reduce human error. Labelling of drum /waste fuel must be clearly marked to differentiate between them and adequate segregation must be in place