Flight Length Sensitive Tasks on B737 Aircraft

A major Maintenance, Repair and Overhaul (MRO) provider contracted VHR Aircraft Technical Services to perform Flight Length Sensitive (FLS) tasks on two Boeing 737 aircraft. The project involved working in confined fuel tank spaces and required strict regulatory compliance. With both aircraft scheduled simultaneously, VHR was responsible for ensuring consistent quality and delivery under tight timeframes.

The work presented several challenges:

• Limited access within wing tanks requiring confined space protocols
• Complex removal of fuel system components and structural elements
• High volumes of degraded sealant to be removed and reapplied
• Full alignment with OEM specifications and regulatory standards

VHR deployed two specialist teams under the direction of a single Team Leader to ensure consistency, compliance and efficiency across both aircraft.

Phase 1: Access and Initial Inspection

• Removal of fuel system components and structural elements
• Visual inspections and old sealant removal followed by surface cleaning

Phase 2: Non-Destructive Testing (NDT)

• NDT inspections carried out to confirm structural integrity in critical areas

Phase 3: Surface Preparation and Sealant Application

• Surface preparation and reapplication of large volumes of sealant to OEM standards

Throughout the project, VHR worked closely with the client’s management team to align with scheduled maintenance windows, ensuring minimal disruption and seamless integration.