Flying boom refueling boom The flying boom is a rigid, telescoping tube with movable
flight control surfaces that a
boom operator on the tanker aircraft extends and inserts into a receptacle on the receiving aircraft. All boom-equipped tankers (e.g.
KC-135 Stratotanker,
KC-10 Extender,
KC-46 Pegasus) have a single boom and can refuel one aircraft at a time with this mechanism.
History In the late 1940s, General
Curtis LeMay, commander of the
Strategic Air Command (SAC), asked
Boeing to develop a refueling system that could transfer fuel at a higher rate than had been possible with earlier systems using flexible hoses, resulting in the flying boom system. The B-29 was the first to employ the boom, and between 1950 and 1951, 116 original B-29s, designated KB-29Ps, were converted at the Boeing plant at
Renton, Washington. Boeing went on to develop the world's first production aerial tanker, the
KC-97 Stratofreighter, a piston-engined
Boeing Stratocruiser (USAF designation
C-97 Stratofreighter) with a Boeing-developed flying boom and extra kerosene (jet fuel) tanks feeding the boom. The Stratocruiser airliner itself was developed from the B-29 bomber after
World War II. In the KC-97, the mixed gasoline/kerosene fuel system was clearly not desirable and it was obvious that a jet-powered tanker aircraft would be the next development, having a single type of fuel for both its own engines and for passing to receiver aircraft. The 230 mph (370 km/h) cruise speed of the slower, piston-engined KC-97 was also a serious issue, as using it as an aerial tanker forced the newer jet-powered military aircraft to slow down to mate with the tanker's boom, a highly serious issue with the newer supersonic aircraft coming into service at that time, which could force such receiving aircraft in some situations to slow down enough to approach their
stall speed during the approach to the tanker. It was no surprise that, after the KC-97, Boeing began receiving contracts from the USAF to build jet tankers based on the
Boeing 367-80 (Dash-80) airframe. The result was the
Boeing KC-135 Stratotanker, of which 732 were built. The flying boom is attached to the rear of the tanker aircraft. The attachment is
gimballed, allowing the boom to move with the receiver aircraft. The boom contains a rigid pipe to transfer fuel. The fuel pipe ends in a nozzle with a flexible ball joint. The nozzle mates to the "receptacle" in the receiver aircraft during fuel transfer. A
poppet valve in the end of the nozzle prevents fuel from exiting the tube until the nozzle properly mates with the receiver's refueling receptacle. Once properly mated,
toggles in the receptacle engage the nozzle, holding it locked during fuel transfer. The "flying" boom is so named because
flight control surfaces, small movable
airfoils that are often in a
V-tail configuration, are used to move the boom by creating aerodynamic forces. They are actuated
hydraulically and controlled by the
boom operator using a control stick. The boom operator also telescopes the boom to make the connection with the receiver's receptacle. To complete an aerial refueling, the tanker and receiver aircraft rendezvous, flying in formation. The receiver moves to a position behind the tanker, within safe limits of travel for the boom, aided by director lights or directions radioed by the boom operator. Once in position, the operator extends the boom to make contact with the receiver aircraft. Once in contact, fuel is pumped through the boom into the receiver aircraft.
KC-135 boom operator view from the boom pod. While in contact, the receiver pilot must continue to fly within the "air refueling envelope", the area in which contact with the boom is safe. Moving outside of this envelope can damage the boom or lead to mid-air collision, for example the
1966 Palomares B-52 crash. If the receiving aircraft approaches the outer limits of the envelope, the boom operator will command the receiver pilot to correct their position and disconnect the boom if necessary. When the desired amount of fuel has been transferred, the two aircraft disconnect and the receiver aircraft departs the formation. When not in use, the boom is stored flush with the bottom of the tanker's fuselage to minimize drag. In the KC-97 and KC-135 the boom operator lies prone, while the operator is seated in the
KC-10, all viewing operations through a window at the tail. The
KC-46 seats two operators at the front of the aircraft viewing camera video on 3D screens. The US Air Force fixed-wing aircraft use the flying boom system, along with Australia (KC-30A), the Netherlands (KDC-10), Israel (modified Boeing 707), Japan (KC-767), Turkey (KC-135Rs), and Iran (Boeing 707 and 747). The system allows higher fuel flow rates (up to / per minute for the KC-135, but does require a boom operator, and can only refuel one aircraft at a time.
Probe-and-drogue crew practice refuelling from an RAF
VC10 tanker over the Falkland Islands, 2005 The probe-and-drogue refueling method employs a flexible hose that trails from the tanker aircraft. The
drogue (or
para-drogue), sometimes called a
basket, is a fitting resembling a
shuttlecock, attached at its narrow end (like the "cork" nose of a shuttlecock) with a valve to a flexible hose. The drogue stabilizes the hose in flight and provides a funnel to aid insertion of the receiver aircraft probe into the hose. The hose connects to a hose drum unit (HDU). When not in use, the hose/drogue is reeled completely into the HDU. The receiver has a
probe, which is a rigid, protruding or pivoted retractable arm placed on the aircraft's nose or fuselage to make the connection. Most modern versions of the probe are usually designed to be retractable, and are retracted when not in use, particularly on high-speed aircraft. At the end of the probe is a valve that is closed until it mates with the drogue's forward internal receptacle, after which it opens and allows fuel to pass from tanker to receiver. The valves in the probe and drogue that are most commonly used are to a
NATO standard and were originally developed by the company
Flight Refuelling Limited in the UK and deployed in the late 1940s and 1950s. This standardization enables drogue-equipped tanker aircraft from many nations to refuel probe-equipped aircraft from other nations. The NATO-standard probe system incorporates shear rivets that attach the refueling valve to the end of the probe. This is so that if a large side or vertical load develops while in contact with the drogue, the rivets shear and the fuel valve breaks off, rather than the probe or receiver aircraft suffering structural damage. A so-called "broken probe" (actually a broken fuel valve, as described above) may happen if poor flying technique is used by the receiver pilot, or in turbulence. Sometimes the valve is retained in the tanker drogue and prevents further refueling from that drogue until removed during ground maintenance.
Buddy store of the
US Navy acts as a buddy tanker for a
Rafale of the
French Navy over the
Arabian Sea, 2015 A "buddy store" or "buddy pod" is an external pod loaded on an aircraft
hardpoint that contains a hose and drogue system (HDU). Buddy stores allow fighterbomber aircraft to be reconfigured for "buddy tanking" other aircraft. This allows an air combat force without dedicated/specialized tanker support (for instance, a
carrier air wing) to extend the range of its strike aircraft. In other cases, using the buddy store method allows a
carrier-based aircraft to take-off with a heavier than usual weapon load, but less fuel than might be necessary for its tasking. The aircraft would then topped-up with fuel from an HDU-equipped "buddy" tanker, a method previously used by the
Royal Navy in operating its
Supermarine Scimitar,
de Havilland Sea Vixen, and
Blackburn Buccaneers; in the Buccaneer's case using a bomb-bay-mounted tank and HDU.
KC-130 Hercules refuels a pair of USMC
CH-53E Super Stallions, 2011 The tanker aircraft flies straight and level and extends the hose/drogue, which is allowed to trail out behind and below the tanker under normal aerodynamic forces. The pilot of the receiver aircraft extends the probe (if required) and uses normal flight controls to "fly" the refueling probe directly into the basket. This requires a closure rate of about two knots (walking speed) to push the hose several feet into the HDU and solidly couple the probe and drogue. Too little closure will cause an incomplete connection and no fuel flow (or occasionally leaking fuel). Too much closure is dangerous because it can trigger a strong transverse
oscillation in the hose, severing the probe tip. The optimal approach is from behind and below (not level with) the drogue. Because the drogue is relatively light (typically soft canvas webbing) and subject to aerodynamic forces, it can be pushed around by the bow wave of approaching aircraft, exacerbating engagement even in smooth air. After initial contact, the hose and drogue is pushed forward by the receiver a certain distance (typically, a few feet), and the hose is reeled slowly back onto its drum in the HDU. This opens the tanker's main refueling valve allowing fuel to flow to the drogue under the appropriate pressure (assuming the tanker crew has energized the pump). Tension on the hose is aerodynamically 'balanced' by a motor in the HDU so that as the receiver aircraft moves fore and aft, the hose retracts and extends, thus preventing bends in the hose that would cause undue side loads on the probe. Fuel flow is typically indicated by illumination of a green light near the HDU. If the hose is pushed in too far or not far enough, a cutoff switch will inhibit fuel flow, which is typically accompanied by an amber light. Disengagement is commanded by the tanker pilot with a red light. and thus later Russian aircraft may be equipped with probe and drogue. The Chinese PLAF has a fleet of
Xian H-6 bombers modified for aerial refueling, and plans to add Russian
Ilyushin Il-78 aerial refueling tankers. Tankers can be equipped with multipoint hose-and-drogue systems, allowing them to refuel two (or more) aircraft simultaneously, reducing time spent refueling by as much as 75% for a four-aircraft strike package.
Boom drogue adapter units USAF KC-135 and
French Air Force KC-135FR refueling-boom equipped tankers can be field-converted to a probe-and-drogue system using a special adapter unit. In this configuration, the tanker retains its articulated boom, but has a hose/drogue at the end of it instead of the usual nozzle. The tanker boom operator holds the boom still while the receiver aircraft flies the probe into the basket. Unlike the soft canvas basket used in most drogue systems, the adapter units use a steel basket, grimly known as the "iron maiden" by
naval aviators because of its unforgiving nature. Soft drogues can be contacted slightly off center, wherein the probe is guided into the hose receptacle by the canvas drogue. The metal drogue, when contacted even slightly off center, will pivot out of place, potentially "slapping" the aircraft's fuselage and causing damage. The other major difference with this system is that when contacted, the hose does not "retract" into an HDU. Instead, the hose bends depending on how far it is pushed toward the boom. If it is pushed too far, it can loop around the probe or nose of the aircraft, damage the windscreen, or cause contact with the rigid boom. If not pushed far enough, the probe will disengage, halting fueling. Because of a much smaller position-keeping tolerance, staying properly connected to a KC-135 adapter unit is considerably more difficult than staying in a traditional hose/drogue configuration. When fueling is complete, the receiver carefully backs off until the probe refueling valve disconnects from the valve in the basket. Off center disengagements, like engagements, can cause the drogue to "prang" the probe and/or strike the aircraft's fuselage.
Multiple systems Some tankers have both a boom and one or more complete hose-and-drogue systems. The USAF
KC-10 has both a flying boom and a separate hose-and-drogue system manufactured by
Cobham. Both are on the aircraft centerline at the tail of the aircraft, so only one can be used at once. However, such a system allows all types of probe- and receptacle-equipped aircraft to be refueled in a single mission, without landing to install an adapter. Other tankers are equipped with hose-and-drogue attachments that do not interfere with the operation of the centerline boom: many
KC-135s are equipped with dual under-wing attachments known as
Multi-point Refueling System (MPRSs), while some KC-10s and
A330 MRTTs have similar under-wing refueling pods (referred to as Wing Air Refueling Pods or WARPs on the KC-10).
Wing-to-wing A small number of Soviet
Tu-4s and
Tu-16s (the tanker variant was Tu-16Z), used a wing-to-wing method. Similar to the probe-and-drogue method but more complicated, the tanker aircraft released a flexible hose from its wingtip. An aircraft flying alongside had to catch the hose with a special lock under its wingtip. After the hose was locked and the connection was established, the fuel was pumped.
Simple grappling Some historic systems used for pioneering aerial refueling used the grappling method, where the tanker aircraft unreeled the fuel hose and the receiver aircraft would grapple the hose midair, reel it in and connect it so that fuel can be transferred either with the assistance of pumps or simply by
gravity feed. This was the method used on the
Question Mark endurance flight in 1929. ==Compatibility issues==