The exploding fuel cell caused the corner panel of the bulkhead to separate. Photo by Bob King

Thell Fowler shows the damaged fuel panel. Photo by Bill Bartkus

Artisans repair damaged fuel cells on H-60

By Bill Bartkus
NADEP North Island

A full fuel tank is a good thing but too much fuel in the tank is not a good thing. In this case, too much fuel can lead to major problems, which can be costly. But expert artisans from Naval Air Depot North Island can repair those problems.
Such was the situation recently when the H-60 Airframes Branch, Code 6.2.1.7 in Building 306, noticed a cracked bulkhead on a Seahawk helicopter that the Depot inducted for the second step of a Planned Maintenance Interval (PMI) phase. The four-step PMI program is conducted in two-year intervals after a Base Line – formerly Standard Depot Level Maintenance – a major overhaul.
According to Thell Fowler, squadron Sailors perform the PMI-1 step at the squadron, and Depot artisans accomplish the remaining three at the Depot.
“This particular helicopter recently returned from a tour in Afghanistan,” said Fowler. “When we started working on this aircraft, we spotted a crack in the bulkhead and noticed extensive damage between the two fuel cells. “It appears that the damage was caused by adding too much fuel which then put excessive pressure inside the fuel cell and the relief valve didn’t operate correctly.” As a result, the fuel tank exploded and the panel separated.
A Seahawk holds about 3,900 pounds of fuel. “Apparently, the fuel gauge wasn’t operating correctly to indicate that the tank was full,” Fowler said.
“The turnaround time for the second stage of a PMI is usually 70 days if there aren’t any hiccups,” he said. A second-stage PMI includes removing the fuel cells. Fowler said that he estimates it will take at least 1,000 man-hours just to repair the fuel cell in this particular Seahawk. “I’m confident that the artisans will perform an excellent job and have this aircraft up and flying again soon.”
Two mechanics and two sheet metal workers disassembled the fuel cell, and they will reinstall it once it’s repaired.