The contractor’s mistake caused a “near catastrophic fuel tank over-pressurization” and $25 million in damage during that aerial refueling session, the report states. Luckily, no one was hurt.
The report goes on to say, “The PDM subcontractor failed to follow Technical Order (TO) mandated procedures when employing the fuel vent test plug during PDM. Due to the relatively short period of time between take-off and [aerial refueling], the [mishap crew] did not have the opportunity to burn a substantial amount of fuel from the number two fuel tank which could have allowed the “dive flapper” valve to open after the tank’s excessive air pressure decreased to the point where the flapper valve would open. This explains why this mishap did not occur during [aerial refueling] conducted between the time the [mishap aircraft] left the PDM facility and the time of the mishap.