TWA800 B747 Fuel Tank Swiss Cheese Model
The 30th Anniversary of TWA800 is next month, and the accident was found by NTSB and FBI to be detonation of an explosive air/vapor mix in the center fuel tanks. There continues to be denial of this finding, even among some pilots. There are many reasons for the denial, next article I will cover the denial reasons, but one big reason is conflicting eyewitness evidence.
Fuel Vapor Safety
As a chemical engineer, our training is basically to avoid operations in the explosive region of air/vapor mixtures, assuming static or any rogue spark can detonate such mixture. In contrast, aviation industry, particularly U.S. industry (FAA/Boeing) historically felt that they could safely operate in the explosive air/vapor region in the fuel tanks. As long as low voltage wires were used in the fuel tanks, the basic historical finding was that static electricity was not strong enough to set off jet fuel/air vapor explosions.
But the plot thickens: what might be true for brand new aircraft, with fresh wiring insulation and no corrosion on the metal surfaces, starts to get very questionable for a 25-year old B747 like TWA800.
TWA800 simply follows the classic "Swiss Cheese" model of "unlucky" alignment of negative factors leading to an unexpected accident. Here are the main factors:
1. Boeing/FAA Design Philosophy
It was considered acceptable risk to operate with an explosive mixture of jet fuel vapor/air in the fuel tanks. Boeing even intentionally used the center fuel tank as a heat sink to dissipate heat from the air conditioning system, which heats up (partially vaporizes) the jet fuel in the center tank, especially if the center tank in mostly empty. Except for longer flights, Boeing recommended keeping the center fuel tank empty for aviation technical reasons. Of course, "empty" usually means there is small amount or "heel" of residual jet fuel in the center fuel tank.
2. Jet Fuel Volatility Factors
The source of the residual Jet Fuel in the empty center fuel tank was Greece, from the prior flight. In those days, jet fuel in Europe was generally lighter/lower boiling then that from the U.S. due to difference in product demands (USA refiners were maxing out gasoline which EU refiners were maxing diesel). So the fuel was probably prone to partial evaporation to create the explosive mixture.
3. Runway Time
There was enough time spent on the runway at JFK on this summer evening for the residual jet fuel in the empty center tank to heat up due to Boeing's design philosophy of directing heat from the A/C system to the center tanks.
4. Wiring Mixing (High/Low Voltage) and Insulation Aging
A wiring logic mistake somewhat unique to Boeing, even though Boeing knew they needed to avoid sparks in the fuel tanks, Boeing commingled high voltage wires with low voltage wires going to the fuel tanks. It turned out that the early B747's were built with a type of insulation on the wires later found to have deterioration problems, potentially allowing higher voltages to bleed into the lower voltage wiring.
5. Sulfidic Corrosion of Fuel Tank Internals
Jet Fuel contains 2000 ppm Sulfur (0.2 wt%) which over time apparently caused some noticeable build up of copper and/or silver sulfides on some of the connections in the fuel tank. This corrosion layer, even if minor electrically, it needs to be recognized that metal sulfides are generally flammable in air. Sometimes metal sulfides can ignite spontaneously if there is a big enough pile of the material, but in this case I think we have to imagine that static electricity or smaller electric voltages could set off a teeny tiny fire that could be a source of vapor/air detonation.
I am coining a new term to describe this possibility, I call it "electro-pyrophoricity". My first intern job in a petroleum industry corrosion R&D group was to study iron sulfide (FeS) pyrophoricity. I made a small pile of FeS and it burned spontaneously, which pissed off my manager who felt FeS was not inherently pyrophoric. Short story of my life!
And I suppose I should mention, I was peripherally involved in the TWA800 Boeing/petroleum industry joint effort to look for fixes.