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there are no continued airworthiness issues due to sulfide contamination.
The wiring inspections included in-tank and out-of-tank wiring. The wiring was inspected for
cracked, abraded, or overstressed insulation; exposed or broken conductors or shields; inadequate
clearance from structure; missing or loose clamps; and misrouting. There were no chronic issues
associated with this wiring. In the few instances where a discrepancy was found, the situation was
rectified by following normal maintenance procedures. The visual/tactile inspection under
consideration, as noted above, may include FQIS wire inspections for these conditions.
To enhance maintenance procedures and the process of removal and replacement of FQIS wiring
and components, the maintenance manuals are being revised to provide increased awareness of a
proper installation and will include more comprehensive instructions for periodic maintenance and
corrective action. To date, the 747 and 757 manuals have been completed.
The inspection program identified no conditions associated with the fuel quantity indication
system that would affect the continued airworthiness of any Boeing-built airplane. As noted in the
introduction, the FAA has released an AD requiring separation and shielding of FQIS wiring on
the 737 and 747. This action was the result of efforts separate from the inspection program.
5.6.5 Fuel Leaks
Examination for fuel leaks is covered in the existing zonal inspection process. There are existing
maintenance practices in place. The inspection service bulletins attempted to capture conditions
that may not otherwise be visible to the team. There were very few instances of fuel leaks reported
via the inspection service bulletin, and these would be identified by the existing zonal inspections.
No additional maintenance procedures for fuel leaks will be proposed as a function of data
collected from the inspection service bulletins.
5.6.6 Access Doors, Panels, and Openings
After Service Bulletin 747-28-2205 had been released regarding the 747 center wing tank
inspection, the Fuel System Safety Leadership Team (FSSLT) agreed to add fuel tank access
doors, panels, and openings to the inspection criteria. Boeing added the criteria to the 727, 737,
757, and 767 service bulletins.
5.0 Boeing Working Group Report (continued)
August 4, 2000 Industry AFFSP Report Page 53
Other than some miscellaneous damage to the seals and minor corrosion, the only other finding
was an instance where it was observed that maintenance procedures were being misinterpreted,
and fuel tank access door gaskets were not being reinstalled. Changes to Boeing maintenance
manual procedures will be made to clarify proper installation. Existing zonal inspection
recommendations are sufficient for the other conditions noted.
5.6.7 Tank Condition
Examination of the tank conditions and sealant did not identify any significant conditions. There
were no instances of corrosion reported inside the tank and only a few instances reported where
sealant was missing or separating from the structure. Existing zonal inspection recommendations
are sufficient for the conditions noted.
5.6.8 Foreign Object Debris
Exclusion of foreign objects from fuel tanks has always been a priority. Debris in tanks could
cause FQIS anomalies and pump failures. All of the Boeing-built airplane inspection service
bulletins and inspection documents looked for foreign object debris.
The inspections confirmed that the tanks are generally quite clean. There were few reports of
debris found in the tanks. The findings were consistent with past experience and would not have
compromised the continued airworthiness of the airplane.
5.7 Conclusions and Continuing Activities
Boeing, along with a large cross section of operators, has conducted a thorough inspection of the
fuel systems of a large number of in-service airplanes. This collaboratively gathered data on inservice
fuel systems has been supplemented with a comprehensive review of fuel systems design
and manufacture.
Overall, the data and analysis have shown that the basic design, manufacture, performance, and
maintenance of commercial air transport fuel systems are robust. This worldwide inspection
program did not find any significant effects due to aging. Fuel tank systems intrinsically age well
with any degradation over time instead being attributable to specific factors such as improper
actions during tank entries for maintenance.
Likewise, this inspection program did not reveal any effects or degradation attributable to
geographic location. The integrity of fuel tank systems was equivalent for airplanes that operate in
hot, humid environmental conditions and in the presence of salt air.
　
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