Incident Overview

Date: Monday 13 June 2011
Aircraft Type: Boeing B-17G
Owner/operator: Liberty Foundation, Inc.
Registration Number: N390TH
Location: 3 mi SE of Aurora Municipal (ARR), IL – ÿ United States of America
Phase of Flight: Initial climb
Status: Substantial
Casualties: Fatalities: 0 / Occupants: 7
Component Affected: C-channel fuel tank repairC-channel fuel tank repair
Investigating Agency: NTSBNTSB
Category: Accident
On the morning of the accident flight, a fuel leak was detected during a weekend maintenance period. A faint odor and a small amount of smoke were observed in the cockpit, prompting immediate turn and radio contact with the pilot. Upon receiving a fire report from the pilot, the flight crew discovered a significant fire on the left wing, leading to an emergency landing. The fire rapidly spread to the fuselage, and extensive damage occurred, including significant fire on the aft lower wing and fuel tank leakage. Post-incident analysis revealed a partially separated C-channel fuel tank repair, which facilitated the fuel leak. The crack along the weld seam, exacerbated by the initial repair, contributed to the rapid fuel vaporization and fire propagation. The fire’s rapid progression and the presence of flammable fuel vapor/air mixtures likely initiated the in-flight fire.On the morning of the accident flight, a fuel leak was detected during a weekend maintenance period. A faint odor and a small amount of smoke were observed in the cockpit, prompting immediate turn and radio contact with the pilot. Upon receiving a fire report from the pilot, the flight crew discovered a significant fire on the left wing, leading to an emergency landing. The fire rapidly spread to the fuselage, and extensive damage occurred, including significant fire on the aft lower wing and fuel tank leakage. Post-incident analysis revealed a partially separated C-channel fuel tank repair, which facilitated the fuel leak. The crack along the weld seam, exacerbated by the initial repair, contributed to the rapid fuel vaporization and fire propagation. The fire’s rapid progression and the presence of flammable fuel vapor/air mixtures likely initiated the in-flight fire.

Description

The weekend before the accident, a fuel leak was identified. The fuel leak was subsequently repaired, and a final inspection the morning of the accident flight reportedly did not reveal any evidence of a continued fuel leak. Shortly after takeoff, the flight crew noticed a faint odor in the cockpit and a small amount of smoke near the radio room. The flight crew immediately initiated a turn with the intention of returning to the departure airport. About that time, they received a radio call from the pilot of the accompanying airplane advising that there was a fire visible on the left wing. The accident pilot subsequently executed an emergency landing to a corn field. Emergency crews were hampered by the muddy field conditions, and the fire ultimately consumed significant portions airframe. In-flight photographs showed the presence of fire on the aft lower portion of the left wing between the inboard and outboard engines. Located in the same area of the fire were fuel tanks feeding the left-side engines. After landing, heavy fire conditions were present on the left side of the airplane, and the fire spread to the fuselage. A postaccident examination noted that the C-channel installed as part of the No. 1 main fuel tank repair earlier in the week was partially separated. During the examination, the tank was filled with a small amount of water, which then leaked from the aft section of the repair area in the vicinity of the partially separated channel. Metallurgical examination of the repair area revealed a longitudinal fatigue crack along the weld seam. The fatigue nature of the crack was consistent with a progressive failure along the fuel tank seam that existed before the accident flight and was separate from the damage sustained in the emergency landing and postlanding fire. The repair earlier in the week attempted to seal the leak but did not address the existing crack itself. In fact, the length of the crack observed at the time of the repair was about one-half the length of the crack noted during the postaccident examination, suggesting that the crack progressed rapidly during the course of the accident flight. Because the repaired fuel tank was positioned within the open wing structure, a fuel leak of significant volume would have readily vaporized, producing a flammable fuel vapor/air mixture. Although the exact ignition source could not be determined due to the fire damage, it is likely that the fuel vapor and liquid fuel encountered hot surfaces from nearby engine components, which initiated the in-flight fire. Probable Cause: An inadequate repair of the fuel tank that allowed the fuel leak to continue, ultimately resulting in an in-flight fire.

Primary Cause

Inadequate repair of the fuel tank, resulting in a partially separated C-channel fuel tank repair that facilitated the fuel leak.Inadequate repair of the fuel tank, resulting in a partially separated C-channel fuel tank repair that facilitated the fuel leak.

Share on:

Leave a Reply

Your email address will not be published. Required fields are marked *