We are well aware about the Alaska Air flight 1282 incident when a door plug on one of its Boeing 737 MAX 9 blew off the aircraft as the plane climbed to FL160 or 16,000ft. Of course, this raised questions among all travelers? Are all 737 MAX 9 planes equipped with door plugs? What is the use of door plugs? There’s simply just so much questions. Anyway, allow me though to share first what the door plug is and their use on planes like the Boeing 737 MAX 9.
The use of door plugs is a common practice, particularly in adapting aircraft to offer flexible layouts. The Boeing 737 MAX 9, known for being Boeing’s largest single-aisle plane currently in production, has brought this practice into the spotlight. The 737 MAX 9 can seat up to 220 passengers and includes an optional extra door to accommodate the required number of evacuation paths for this seating capacity. However, when airlines choose not to install more than 189 seats, they have the option to replace this additional door with a panel, commonly referred to as a door plug.
Door plugs have been a part of aircraft design for years, allowing airlines to customize their planes according to specific needs and preferences. The decision to use a door plug is influenced by various factors, including the desired seating capacity and the associated costs of maintaining additional emergency exits.
The Technical Aspects of the 737 MAX 9 Door Plug
The door plug on the 737 MAX 9 is a critical component, ensuring the safety and integrity of the aircraft’s structure. A detailed diagram provided by the U.S. National Transportation Safety Board (NTSB) reveals the complexity of this component. The plug, measuring 26 by 48 inches (66 by 122 cm) and weighing 63 pounds (29 kg), is held in place by four bolts—two in the upper corners and two lower hinge brackets. Additionally, it features two straps and two bonding jumpers near the bolts.
To further secure the plug, “stop fittings” are positioned at 12 different locations along the side of the plug and the door frame. These fittings play a crucial role in holding the plug in place, preventing it from being pushed out of the airframe. The NTSB’s investigation into the door plug’s attachment and the presence of bolts is ongoing, with the aim of determining whether the component was properly attached.
Safety Considerations and Regulatory Compliance
The use of door plugs in aircraft like the Boeing 737 MAX 9 raises important questions about safety and regulatory compliance. Airlines operate under various expenses, and functioning emergency exits come with their own set of costs. These include routine maintenance, inspections, and staffing by flight attendants during takeoff and landing. By sealing off an emergency exit with a door plug, airlines can reduce these associated costs.
However, the safety of passengers remains a paramount concern. In the United States, federal aviation regulations dictate the minimum standards for emergency exits based on aircraft seating capacity. For instance, a Boeing 737 Max 9 with fewer than 190 seats, like the Alaska Airlines Max 9, is allowed to disable certain exits and use door plugs under these regulations. This practice is authorized and complies with federal rules, but it does prompt the question of whether all exits should be available for use in emergencies, regardless of the aircraft’s seating capacity.
The issue becomes more complex when considering that Boeing sells the same airplane model to different airlines with varying needs. For example, lower-cost global airlines such as Jakarta-based Lion Air may opt for a dense seating configuration requiring more emergency exits, while U.S. carriers often choose configurations with fewer seats and consequently fewer required exits.
Personal Thoughts
While I understand the financial concerns of having a door plug instead of an emergency exit door, shouldn’t safety always be paramount, even if it comes at a cost? Although additional exit doors can be a financial constraint and airlines can save money by having them replaced with plugs, lives don’t have a price and can never be replaced.
Just like the MCAS issue on the Boeing 737 MAX that led to more than 300 lives lost in two separate air crash incidents, Boeing seems to prioritize competing and acquiring more customers over ensuring safety. The 737 is a 1960s aircraft, and upgrading it to compete with the more modern Airbus A320neo has its limitations. For now, I hope that a solution is found to prevent such blowouts in the future that could once again cost lives.
First love never dies. I fell in love with airplanes and aviation when I was a kid. My dream was to become a pilot, but destiny led me to another path: to be an aviation digital media content creator and a small business owner. My passion for aviation inspires me to bring you quality content through my website and social accounts. Aviation is indeed in my blood and blog!
