Memphis Int'l Airport TN/2001
Date 22 Dec 2001 Cause: Mechanical Failure Condition D/N n/a Wing/Base: 164 AW/TN ANG Location: Memphis Int'l Airport TN IMC/VMC n/a Tail #:
Fatalities: none Fatigue? yes
Synopsis: An incomplete maintenance procedure led to failure of the left wing structure during ground refueling. Two maintenance workers were injured.
While preparing for an Operation "Enduring Freedom" mission to Ramstein AB, Germany , maintenance personnel found a fuel leak in the aircraft's left wing, near #2 engine pylon. A fuel cell maintenance specialist team was called and repaired the leak. On completion of the repair procedure, on of the technicians failed to remove the left wing fuel tank vent plug, as required by the T.O.
Later in the day, the aircraft was refueled prior to the Ramstein mission. During the refueling process, trapped fuel vapor overpressurized the fuel tanks, causing the failure of the wing structure, and > of the wing. There was no fire. Approximately 3300 gallons of fuel was spilled onto the ramp and drained into a nearby creek. Two maintenance workers were injured, one with a broken leg and the other with a strained shoulder.
The entire C-141 fleet was immediately grounded, pending investigation. The investigators noted that the unit was stretched thin due to a high operations tempo, with 4 of 5 assigned aircraft and the majority of the unit already deployed. They noted that two supervisors signed off on the repair without actually inspecting the work. The aircraft was declared a total loss and was dismantled.