Boeing Faces Fresh Safety Concerns Over Electrical Flaw in 777 Aircraft That Could Cause 'Fuel Tank Explosion'

Embattled US aircraft maker Boeing has identified a big flaw in its 777 aircraft fleet that could lead to onboard fires. The problem arises from inadequate electrical insulation near the fuel tank, according to a proposal from the US Federal Aviation Administration (FAA) in March.

If left unaddressed, the flaw could trigger ignition within the fuel tank, resulting in fires or explosions, the New York Post reported. The affected aircraft include nearly 300 Boeing 777s across the US, spanning various models such as the 77–200, –200LR, –300, –300ER, and 777F series. After Boeing disclosed the issues, the FAA proposed a $14 million solution to rectify the issue across all 292 affected US-registered airplanes.

This solution entails installing electrical bonding and grounding components in the center fuel tank, as outlined in the proposed Airworthiness Directive (AD) issued by the FAA. The proposed repairs involve thorough inspections, lasting approximately 90 hours per aircraft, followed by the installation of Teflon sleeves and cap fasteners in specific areas of the fuel tanks.

This fix comes after a similar directive issued by the FAA in 2017, aimed at addressing electrical issues in several Boeing 777 models. The goal is to prevent arcing inside the main and center fuel tanks, which, when combined with flammable fuel vapors, could lead to explosions and aircraft losses. The US regulator’s report prompted Boeing to respond by May 9. If approved, Boeing would have up to 60 months to complete the necessary repairs.

Boeing has expressed its support for the FAA’s proposal, stressing that the issue does not pose an immediate safety-of-flight concern. Despite being an older aircraft, the Boeing 777 is widely used worldwide. The Boeing 777 fleet has been operational for nearly 30 years, transporting over 3.9 billion passengers. However, in recent months, Boeing’s aircraft have faced heightened scrutiny due to various safety issues, including a January incident where a door plug blew out during an Alaska Airlines flight. Earlier, Boeing said its leaders are committed to cooperating with the FAA probe.

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