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An investigation traced the failure to a manufacturing defect on a fuel pipe that caused the third-stage engine to shut down.
One of the two engine covers cut through a fuel pipe and the plane scattered debris – including chunks of metal weighing up to 37kg – across the Heathrow runway.
A punctured fuel pipe in the right engine caused it to catch fire, and the 50-year-old captain was forced to turn around and make an emergency landing, with passengers evacuating on the slides.
The risk of having an unlagged hot air pipe running close to a fuel pipe was identified by an RAF board of inquiry last December as being the most likely cause of the crash.
Although the city made some design changes to address the concerns -- moving a fuel pipe that would have run from the tank up an elevator shaft, for example -- it left the tank in place.
David Strait, 27, an inspector who works for United Space Alliance, a NASA contractor that services the shuttles, said he was looking into a fuel pipe with a flashlight when he spotted a tiny crack.
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The shuttle fleet has been grounded since June because of cracks in metal liners in fuel pipes.
MECHANICS checking for a blockage in a car's fuel pipes know to floor the accelerator, for a splutter then indicates a problem that may not show up when the engine is idling.
Engineers for the space agency said they did not know the cause of the cracks in the liners, inside the fuel pipes that carry supercold hydrogen to the shuttles' three main rocket engines, or what danger they might pose.
Ron Dittemore, the space agency's shuttle program manager, said all four shuttles had apparently been flying for years with small fractures in metal sheets that line some fuel pipes.
Ainsworth said Brown demanded the grounding of the entire Nimrod fleet even though repairs to the relevant faulty hot-air ducts and fuel pipes on the remaining aircraft had taken place.
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