Tag: #Boeing

Missing Bolts on Qantas’ Boeing 737 Engine

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Tsamouris, the Fastener Specialists©

A pilot with the Australian airline Qantas raised concerns about the airline’s maintenance standards after
sharing shocking footage of a Boeing 737 plane missing three out of four bolts and a seal on an engine air
duct. The video, tweeted by journalist Michael West in September 2023, showed that the missing pieces had
fallen into the plane’s cowl.

According to West, the maintenance work on the plane was carried out in Brisbane, and the issue was
identified by engineers on a Saturday. While the missing bolts could have potentially led to a fire onboard,
West admitted that suggesting the plane could have crashed would be too alarmist.

Qantas stated that safety had always been their top priority and that an investigation was underway to
determine how the defects occurred. The airline also emphasized that the air duct takes air away from the
engine and does not impact its operation.

West has raised concerns about Qantas’ cost-cutting measures and outsourcing, suggesting that these
factors may be contributing to mounting problems with the airline’s planes. He also pointed out that
regulators inspect Qantas planes before takeoff to ensure their safety.

Fasteners Broke off Wing during Southwest Airlines Flight

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Passengers on a Southwest Airlines flight from Austin to Harlingen, Texas, in December 2015 experienced a
harrowing ordeal when a piece of the wing allegedly “fell off” during the journey. The Boeing 737, carrying
109 passengers and five crew members, was forced to make an emergency landing at San Antonio Airport.

Passenger Lorenzo Hernandez Jr. described the incident as a “near death experience,” recounting how
fasteners on the left side of the plane’s wing broke or came off, causing a panel to hang loose. He reported
that some passengers screamed to the aircrew as the plane experienced severe turbulence, with many
praying in the cabin.

Despite the frightening situation, Hernandez praised the staff and pilots for keeping calm and stabilizing the
plane. A Southwest spokesperson confirmed that the captain decided to divert the flight due to a flap track
canoe fairing appearing at an irregular angle. The aircraft landed safely without incident, and no injuries
were reported.

Another passenger, Hayden Ellis, recalled the pilot announcing over the tannoy that something had fallen off
the wing, while Clarissa Ellis mentioned that a flight attendant was alerted to the issue by a concerned
passenger.

Screws Coming Loose on Jet Wing Mid-Air

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Tsamouris, the Fastener Specialists©

In March 2023, a video surfaced on social media showing three screws visibly shaking on the left wing of a
TAAG Angola Airlines Boeing 737-700 aircraft during flight.

The video, which quickly went viral, raised serious questions about the maintenance and safety standards of
the state-owned airline, which serves as the flag carrier of Angola. TAAG Angola Airlines, headquartered in
Luanda, operates domestic flights within Angola, as well as medium-haul services in Africa and long-haul
routes to Brazil, Cuba, and Portugal.

The incident highlighted the critical importance of proper maintenance and regular inspections of aircraft,
particularly in areas that are subject to high stress and vibration, such as the wings. Loose or missing
fasteners can potentially lead to structural issues, compromising the safety of passengers and crew.

How a Loose Bolt Led to China Airlines Boeing 737 Explosion

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In August 2007, a seemingly minor maintenance oversight led to a near-fatal accident during China Airlines
Flight 120. Fortunately, there were no casualties. The Boeing 737-800, carrying 157 passengers and 8 crew
members, caught fire and exploded at Naha Airport in Japan shortly after landing safely from Taipei and after
all passengers had evacuated.

The incident unfolded as the crew prepared for disembarkation, having taxied the aircraft to the gate and
shut off the engines. Suddenly, ground crew members noticed flames emanating from one of the engines
and promptly informed air traffic control. The captain, upon being alerted, ordered an emergency evacuation.
Miraculously, all passengers and crew managed to evacuate the aircraft through the four hatches using
slides, just moments before the plane exploded. The pilots, having ensured everyone’s safety, exited through
the cockpit window. Despite the harrowing experience, only minor injuries were reported.

The on-site investigation revealed that fuel had leaked from a puncture hole in a slat’s track. Further inquiry
uncovered that an incorrectly installed bolt in the right-wing of the aircraft’s slat down-stop had worked itself
loose. The bolt had been torqued without the requisite washer during scheduled maintenance six weeks
prior. Consequently, the nut came loose, causing the entire down-stop assembly to detach and fall onto the
slat-can assembly track during ground movement.

As the slat retracted, it pushed the detached assembly, eventually forcing the downstop bolt through the
slat-can wall, puncturing the fuel tank. The leaking fuel ignited upon contact with high-temperature areas on
the right engine, leading to the fire and explosions.

Shockingly, the cause of this near-disaster was traced back to a single missing washer, which was found
lying just below the opening in the wing forward spar.

In the aftermath of the incident, the Republic of China Civil Aeronautics Administration grounded the entire
fleet of Boeing 737-800s operated by China Airlines, Mandarin Airlines, and the Republic of China Air Force
for fuel system inspections. The Japanese Civil Aviation Bureau followed suit, requesting inspections of
aircraft of the same type operated by Japanese carriers.

Loose Wing Screw on Air China Boeing 737 Flight

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In July 2022, Air China found itself in the spotlight after a passenger on flight CA1921 from Beijing to
Hengyang noticed and recorded a loose wing screw on the Boeing 737NG aircraft. The video, which was
shared widely on Chinese social media platform Weibo, prompted the airline to take swift action and issue a
statement addressing the incident.

According to the statement, Air China “attached great importance” to the loose screw in the inboard canoe
fairing of the left flap and immediately inspected the relevant parts of the aircraft, repaired the loose screws,
and checked the entire fleet for similar issues.

The inboard canoe fairing, where the loose screw was located, is primarily used to regulate airflow, reduce
drag, and save fuel. The screws in question are responsible for fixing the flap track fairing tail cones, which
are a part of the inboard canoe fairing.

While there was no official explanation for the cause of the loose screw or its potential impact on flight
safety, aviation experts weighed in on the matter. Qiu Qing, an aviation blogger with over 300,000 followers
on Weibo, suggested that the issue could be attributed to either a broken supporting target in the fairing or
long-term vibration at the screw’s position.

According to the configuration deviation list (CDL) of the Boeing 737NG, it is acceptable for the aircraft to
take off without up to two flap track fairing tail cones. Veteran pilot Chen Jianguo told the Beijing Youth Daily
that one or two loose screws on the fairing would not affect safety, even if the fairing itself were missing.

Boeing Finds Missdrilled Rivet Holes on 50 Undelivered 737 Max

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Back in February 2024, Boeing announced that it has discovered incorrectly drilled holes in the fuselages of
approximately 50 undelivered 737 Max jets. This setback was expected to cause rework and potentially delay
the delivery of these planes, raising further concerns about quality control at the manufacturer and its
suppliers.

Stan Deal, the CEO of Boeing’s commercial plane unit, stated in a memo to employees that a supplier had
identified two holes that may not have been drilled according to the company’s requirements. While Deal
emphasized that this issue is not an immediate flight safety concern and that the 737s currently in use can
continue flying, it underscores the ongoing challenges faced by Boeing and its suppliers in maintaining high
standards of quality and safety.

The latest problems come on the heels of a January 5th, 2024, incident involving a 737 Max 9 jet operated by
Alaska Airlines, in which a panel blew out mid-flight due to missing bolts, forcing an emergency landing and
the grounding of some Max 9s in the United States. Reports have suggested that Boeing workers had
previously opened and reinstalled the panel that blew off the Alaska Airlines plane, raising further questions
about quality control practices.

In response to these issues, the Federal Aviation Administration (FAA) has stated that it will limit Boeing’s
output until it is confident in the company’s quality control processes. The regulator is also investigating
Boeing’s manufacturing practices and production lines, including those involving Spirit AeroSystems,
Boeing’s fuselage supplier.

At Tsamouris, we understand the critical importance of quality control and precision in the manufacturing
process, particularly when it comes to fasteners and components that play a vital role in ensuring the safety
and reliability of aircrafts.