British Aerospace Plc BAe 146-200, VH-JJU

Safety Action

On 6 September 1999, the Australian Transport Safety Bureau issued recommendation R19990052 to the Civil Aviation Safety Authority. That recommendation stated that:

"The Civil Aviation Safety Authority, in conjunction with the aircraft manufacturer, British Aerospace Plc, address deficiencies that permit the entry of fumes into the cockpit and cabin areas of BAe 146 aircraft. These deficiencies should be examined by the regulatory authority as part of its responsibilities for initial certification and continued airworthiness of the BAe 146 aircraft."

The Civil Aviation Safety Authority responded on 14 March 2000 stating:

"In the lengthy period between the incident and the release of your report, CASA has investigated this issue in considerable detail, in conjunction with the aircraft manufacturer and the major Australian operators. As a result of this work, and discussions with the certifying authority (the UK Civil Aviation Authority), CASA is satisfied that the BAel46 aircraft in service in Australia are safe for public transport. CASA technical specialists are available to brief your investigators on the scope and findings of this work.

"As your recommendation does not specify the nature of any additional deficiencies that the Bureau believes need to be addressed by CASA and the aircraft manufacturers, I am seeking details of any deficiencies that you believe have not been appropriately dealt with. It would also assist us in providing a meaningful and constructive response to your recommendations if you were to provide us with details of any incidents that have occurred since the original incident in 1997.

"In the meantime, we will continue to monitor the situation and review any information that comes to hand."

The Bureau classified the response as "Open" and has initiated further correspondence with CASA. On 12 October 2000, the Senate Rural and Regional Affairs and Transport References Committee tabled its report into Safety and Cabin Air Quality in the BAe 146 Aircraft. The Government tabled its response to the References Committee's report on 28 June 2002.

Analysis

The cabin manager's observations, during the take-off roll, of a smoky burning smell, and her subsequent symptoms, suggested contamination of the cabin air supply with the by-products of engine combustion. Her blood test results, appearing consistent with CO exposure, seemed to confirm that hypothesis. Although maintenance engineers traced the source of oil contamination to the number 3 engine, the investigation was unable to positively determine the exact origin of the fumes that affected the cabin manager. At the stage of flight when fumes affected the cabin manager, the air conditioning packs were being supplied with air from the APU, not from the engines.

It was considered possible that, at some stage prior to the flight, air conditioning pack number two was contaminated with the by-products of the thermal degradation of oil from the number 3 engine. That would have resulted in the tainting of the APU air as it passed through air conditioning pack two before entering the cabin. It is also possible that the cabin air became contaminated from an external source. While taxiing, the aircraft's engine exhaust or a preceding aircraft's engine exhaust may have been ingested into the APU air intake, resulting in the cabin air contamination.

The fumes had a detrimental effect on the well being of the cabin manager. The potential effect on her ability to effectively carry out her duties in the event of an emergency could not be determined.

Summary

During the take-off roll, the cabin manager of the BAe 146 aircraft became aware of a smoky, burning smell coming from an air vent in the region of her crew seat at the forward (L1) exit door. Initially there was a mild odour. That was followed by the rapid onset of strong fumes for a short period after which the fumes dissipated quickly. The event was of 2-3 minutes duration.

The cabin manager felt overwhelmed by the fumes and was on the verge of passing out when her colleagues became aware of the situation and provided her with portable oxygen. After approximately 10 minutes of using oxygen, the cabin manager felt well enough to attempt a resumption of her duties but was unable to continue due to the effect of the fumes exposure.

The cabin manager, who had ten years of operational experience on the BAe 146, spent the duration of the flight seated at the rear of the aircraft; breathing portable oxygen for most of that time. The cabin manager reported that when she was not using oxygen she felt unwell, she had difficulty in thinking clearly and she found it difficult to coordinate her thoughts with her actions. No other members of the crew or any of the passengers reported being affected by the fumes.

Upon arrival in Kununurra, engineering inspections were performed on the aircraft and further action was deferred in accordance with the Civil Aviation Safety Authority airworthiness directive AD/BAe146/086. That airworthiness directive required certain actions to be performed whenever a cabin air quality problem was identified, which was suspected of being associated with oil contamination of the air supply from the air conditioning packs. Subsequent engineering inspections revealed that the cause of the oil contamination was a worn number one bearing seal in the number 3 engine. The engine was replaced and no further fumes were evident during following flights.

The cabin manager sought medical treatment and tests in Kununurra on the day of the incident and in Perth on the following day. Although she was eventually cleared to return to work, symptoms of anxiety, impaired judgement, and light-headedness remained with her for in excess of one week. Of note was the result of a blood test that revealed she had been exposed to a higher than normal level of carbon monoxide (CO). When inhaled, CO combines with the haemoglobin, the blood's oxygen-carrying molecule, to form carboxyhaemoglobin (COHb). Once in that state, the haemoglobin is unable to carry oxygen. Thus, the blood's ability to carry oxygen to body tissues, including vital organs such as the heart and brain, is inhibited.

CO is the product of incomplete combustion of carbonaceous material. It is found in varying amounts in the smoke and fumes from burning aircraft engine fuels and lubricants. The gas itself is colourless, odourless, and tasteless but is usually mixed with other gases and fumes that can be detected by sight or smell. Individuals that have been exposed to CO should be removed from the exposure and administered 100 percent oxygen through a tight fitting mask until all symptoms have been resolved. If blood testing for measurement of COHb level is required, the samples should be drawn as soon as possible after the exposure, as COHb has a short half-life in the body of 4-5 hours. If an individual is administered 100 percent oxygen, the half-life is reduced to 40 to 80 minutes.

The same aircraft was the subject of a pilot report three days prior to the cabin manager's experience, in which an oil-like smell was evident in the cockpit but not in the cabin. The event was of short duration and occurred just after take-off, when the source of air supply was changed from the Auxiliary Power Unit (APU) to the engines. Inspection by maintenance engineers of the engines, APU, and air-conditioning system revealed no signs of contamination and the defect was cleared.

Evidence from previous incidents of air system contamination on this type of aircraft has indicated that fumes were associated with engine or APU oil contamination of the air conditioning system. The BAe146 is similar to many aircraft in that the supply of cabin air originates in the aircraft's engines. Air is bled from the final stage of the engine's high-pressure compressor just prior to the combustion chamber. The air destined for the cabin then passes through a catalytic converter in order to clean the air of any oil contaminants. Catalytic converters operate at maximum efficiency under highly specific conditions of temperature and contaminant to air ratio. The air is then passed through a heat exchanger and then through one of two air conditioning packs before entering the cabin. During normal operation bleed air from engines one and two is fed to pack one, which in turn supplies conditioned air to the flight deck and cabin. Bleed air from engines three and four is fed to pack two, which normally only supplies air to the cabin. Additionally, bleed air from the APU is used by either pack during the take-off and landing phases or when air conditioning is required on the ground.

Occurrence summary

Investigation number 200103238
Occurrence date 18/07/2001
Location Perth, Aero.
State Western Australia
Report release date 04/07/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Fumes
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer British Aerospace
Model BAe 146
Registration VH-JJU
Serial number E2116
Sector Jet
Operation type Air Transport High Capacity
Departure point Perth, WA
Destination Kununurra, WA
Damage Nil

Boeing 747-400, VH-ANA, north-east of Mount Isa, Queensland, on 13 July 2001

Safety Action

During the investigation a number of unrelated issues were found. These related to controller operation of CPDLC. Airservices Australia is proposing a national review of those procedures during early 2002.

The investigation also found that the Aeronautical Information Publication did not include CPDLC as a form of communication, yet examples were included with only a limited explanation. This was reported to the Civil Aviation Safety Authority (CASA) for action. CASA subsequently advised that additional material was warranted in the AIP.

On 29 November 2001 AIP amendment A/L 32 was issued. The amendment contained changes to the Communication section that included more detail on CPDLC operation.

Analysis

It is probable that the crew's efforts to regain time during the flight became their primary focus. Thus, when the fuel transfer problem arose, they concentrated on that item to ensure that the flight could continue to make up time. That action caused them to be distracted from managing the flight in accordance with air traffic control instructions.

As the controller acted to ascertain the actual level of the B747, it appears that the crew became aware that they had not descended in accordance with their clearance. As they descended the B747 they may have became focused on that task to the detriment of monitoring the VHF radio. While it was probably appropriate to give priority to managing the aircraft's descent, a short transmission advising their intended action would have assisted the controller to appreciate the possible effect on the airways system.

The use of ambiguous annotations by the flight crew to note the descent requirement, probably did not assist them in monitoring their flight progress.

Summary

The Boeing 747-400 (B747) was tracking northwest on air route R340 at flight level (FL) 330 and estimated TASHA, a position 61 NM northeast of Mount Isa, at 1530 Eastern Standard Time. The Boeing 737-400 (B737) was tracking northeast on air route J64 at FL330 and estimated TASHA at 1531. The Isa sector controller, located in the Brisbane Air Traffic Control Centre, identified the potential conflict between the aircraft and offered the B747 crew a change of level to FL350. The crew preferred a lower level due to the ability to maintain a greater ground speed; the flight had departed later than scheduled and the crew were endeavouring to make up time en route.

At 1501, the controller instructed the B747 crew to descend, when ready, to FL310 with a requirement to reach that level by 31 NM southeast of TASHA. That position was the lateral separation point between the air routes and the controller required the 2,000 ft vertical separation standard to be established between the aircraft before they entered the area of conflict. The pilot in command (PIC) readback the amended clearance in accordance with Aeronautical Information Publication (AIP) procedures. Subsequently, the crew did not descend the aircraft in accordance with the clearance and it entered the area of conflict at FL330. There was an infringement of separation standards as the required vertical standard was not achieved before the aircraft entered the area of conflict.

At about 1508, a change of controllers occurred at the Isa sector position. The new controller instructed the B747 crew to change frequency at 1512. The crew contacted the Isa controller on the new frequency and reported maintaining FL330. The AIP required a crew operating in controlled airspace to report, after any en route frequency change, the last assigned level and whether the aircraft was on climb, in the cruise, or on descent. The crew did not report the assigned level of FL310 and the controller did not query the crew regarding that report.

The controller became concerned, as the B747 approached the lateral separation point, by the lack of a report indicating that the aircraft was on descent to the amended level. The AIP required a report from a crew when an aircraft had left a level at which level flight had been conducted in the course of a climb, cruise, or descent.

The controller conducted a single interrogation (one shot) of the aircraft's automatic dependant surveillance (ADS) system and attempted to contact the crew by very high frequency (VHF) radio. Automatic Dependant Surveillance was a system dependant on a datalink and a series of reporting `contracts' (a rate of reporting) established between an aircraft and a ground system. The Australian Advanced Air Traffic Control system (TAAATS) automatically initiated contracts and specified the type of report, the content of a report, and the reporting frequency required. As the contracted reporting occurred automatically, it required no flight crew action. There was no cockpit indication that a "one shot" request had been actioned by an aircraft's ADS system.

The ADS response from the aircraft at 1527 indicated that it was maintaining FL330 and was 26 NM from TASHA, within the area of conflict. The controller again attempted to contact the crew by radio and also by the controller pilot datalink (CPDLC) facility. The controller made another "one shot" interrogation of the aircraft's ADS. That ADS response at 1529 indicated that the aircraft was at FL329 and 14 NM from TASHA.

Flight crews were required to maintain continuous communications with air traffic control while in controlled airspace and within VHF radio coverage. Crews of ADS equipped aircraft were able to report to ATC using that facility; however, they were required to communicate using VHF radio when operating within radio coverage. The B747 was operating in non-radar airspace and the crew reported their position via ADS. The route was within VHF radio coverage for the sector.

The controller was about to instruct the B737 crew to climb to FL340 when an ADS altitude report of FL312 was received from the B747. That report established that the 2,000 ft separation standard had been achieved as it was within 200 ft of the assigned level.

At 1529:43, after five unsuccessful attempts to contact the B747 crew on VHF radio, the controller asked the crew of the B737 (on the crossing route) to contact the B747 crew and have them call on 125.2 Mhz. At 1531, the B747 crew contacted the controller on the VHF radio and reported maintaining FL310. At the same time the B747's ADS issued a Waypoint Report for TASHA which reported the aircraft's level as FL309. Later analysis of the ADS reports indicated that the B747 had descended 1,700 ft in about 28 seconds.

The automatic reporting rate for ADS tracks was set by TAAATS. The flight information region was divided into cells that were allocated a reporting rate for a Basic Report. The rate was normally 30 minutes (or 40 minutes for oceanic areas). A controller with the jurisdiction of an aircraft on an ADS track can manually amend the rate as required. Also, when the aircraft passed a designated waypoint the system automatically generated a Waypoint Change Event report that was appended to a Basic Report. Furthermore, an Altitude Range Event report was automatically generated when an aircraft left a contracted vertical range. When in the cruise, that vertical range was plus or minus 200 ft of the cleared flight level (CFL). Assignment of an amended level reset the range. When on climb, the reset range was the present level minus 200 ft to CFL minus 200 ft, with the reverse range for aircraft on descent. At that time, for the B747 maintaining FL330 and then assigned FL310, the vertical range would change from FL332 - FL328 to FL332 - FL312. As the aircraft descended through FL312 the Altitude Range Event report was generated and the contract reset to FL312 - FL308; to monitor the amended CFL (FL310).

The B747 PIC later reported that they had endeavoured to remain at FL330 for as long as possible due to turbulence at FL310 that would have likely required a speed reduction, which in turn, would have constrained their efforts to make up time during the flight. At the time of the issue of the amended clearance, the PIC was the pilot flying the aircraft and the first officer had left the flight deck shortly before to take a break. On the return of the first officer, the PIC briefed him on the clearance as per company procedures and the FO wrote the clearance on the flight plan. The incident report submitted by the crew stated that the annotations used by the FO on the flight plan indicated that descent should commence at 31 NM from TASHA, instead of the requirement to be at FL310 at that point.

The crew then became involved in troubleshooting a problem with balancing the main fuel tanks. The PIC stated that they had been distracted and forgot about the requirement to descend to FL310 by 31 NM southeast of TASHA. The PIC reported that he was aware of the B737 on the crossing track as he had heard the controller request the B737 crew to contact them (the B747 crew).

The South Pacific Air Traffic Services Coordinating Group's Southern Pacific Operations Manual (SPOM) V3.1 set the standard for ADS operations for air traffic control service providers and operators. The system status and serviceability was checked following the occurrence. Between 1332 and 1719 there were 31 downlink messages of which the minimum transit time was 6 seconds and the maximum transit time was 24 seconds. Those times were within the required SPOM system performance parameters. During that period there were no reported failures of the communication or TAAATS systems.

The investigation did not establish why the B747 crew did not respond to the controller's radio calls.

Occurrence summary

Investigation number 200103079
Occurrence date 13/07/2001
Location 46 km SE TASHA, (IFR)
State Queensland
Report release date 17/04/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-ANA
Sector Jet
Operation type Air Transport High Capacity
Departure point Sydney, NSW
Destination Hong Kong
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 737
Registration VH-TJP
Serial number 24441
Sector Jet
Operation type Air Transport High Capacity
Departure point Yulara, NT
Destination Cairna, QLD
Damage Nil

Sikorsky S-76C, VH-EXX

Safety Action

Local safety action

Operator

Following this occurrence, the operator conducted a one-time borescope inspection of its fleet centrifugal diffusers for cracks. No cracks were discovered.

Engine manufacturer

The engine manufacturer has discontinued the installation of all modification TU204 GG turbine blades at its factory and at repair centres. On 26 November 2001, Turbomeca issued service bulletin (SB) 292 72 0258 with applicability to all Arriel 1B engines (single engine variants), which recommends removal of modules with modification TU204 embodied.

In addition, the manufacturer has implemented dimensional checking on all new Arriel model engine module three assemblies, for turbine blade platform/GG disc interferences and on this operator's engines with more than 1,000 hours time accumulated on a module three.

RECOMMENDATIONS

As a result of the investigation, the Australian Transport Safety Bureau has identified a safety deficiency related to Turbomeca Arriel engine fire propagation following turbine blade failure and rear bearing collapse. The Australian Transport Safety Bureau therefore issued the following recommendations.

R20010192 issued on 18 September 2001

The Australian Transport Safety Bureau recommends that the Australian Civil Aviation Safety Authority assess the adequacy of the Turbomeca Arriel engine module three bearing lubrication installation to determine if it meets the applicable design standard requirements to ensure the continued airworthiness of relevant Australian registered aircraft.

Australian Civil Aviation Safety Authority response received on 25 February 2002:

"CASA advised the Direction Generale de L'Aviation Civile (DGAC) of the ATSB determination that an engine fire occurred as a result of engine failure. CASA notes that the DGAC does not support the ATSB determination. CASA has no evidence of the Turbomeca Arriel Module 3 bearing lubrication system not satisfying turbine engine certification standards. CASA notes that the DGAC, in advice to the ATSB dated 31 December 2001, has determined the Arriel 1 engine complies with the latest requirements of JAR-E-530 "Fire"."

Australian Transport Safety Bureau response classification- CLOSED-NOT ACCEPTED

Physical evidence and pilot reports substantiate the occurrence of fire. The failure mode of oil tube separation has still not been proven to meets the applicable design standard requirements to ensure the continued airworthiness of relevant Australian registered aircraft.

R20010193 issued on 18 September 2001

The Australian Transport Safety Bureau recommends that the Direction Generale de l'Aviation Civile assess the adequacy of the Turbomeca Arriel engine module three bearing lubrication installation to determine if it meets the applicable design standard requirements.

Direction Generale de l'Aviation Civile response received on 15 January 2002:

"In light of the incidents related in your referenced document, DGAC determined that the Arriel 1 engine complies with the latest airworthiness requirement, i.e. JAR-E-530 "Fire" under "Notice for Proposed Amendment "NPA-E-24 and interpretative material NPA-E-37 (note: these requirements result from the harmonisation with FAR 33, but are not significantly different from current JAR-E requirements)."

Australian Transport Safety Bureau response classification- MONITOR

The Direction Generale de l'Aviation Civile response proposes a change to the applicable regulation. The Australian Transport Safety Bureau will monitor that proposed change.

The Australian Transport Safety Bureau has also identified a safety deficiency related to Turbomeca Arriel engine gas generator turbine blade failures. The Australian Transport Safety Bureau therefore issued the following recommendations.

R20010196 issued on 18 September 2001

The Australian Transport Safety Bureau recommends that the Australian Civil Aviation Safety Authority take appropriate action to ensure the continued airworthiness of Australian registered aircraft fitted with Turbomeca Arriel engines incorporating modification TU204.

Australian Civil Aviation Safety Authority response received on 25 February 2002:

"CASA has been advised that the engine manufacturer, Turbomeca, cancelled the incorporation of Modification TU 204 in 1998. The DGAC has advised of action to be taken to address engines in service incorporating TU204. CASA notes that the DGAC, in advice to the ATSB dated 31 December 2001, advises the DGAC will be issuing an Airworthiness Directive to require the mandatory removal of turbine blades incorporating modification TU 204. The Directive is to be limited to single engine helicopters. CASA will review the DGAC Airworthiness Directive on its receipt and advise the ATSB of the results of that review. CASA looks forward to receiving a final briefing on the conclusions of the ATSB investigation of Occurrence No. 200103038."

Australian Transport Safety Bureau response classification- MONITOR

The Civil Aviation Safety Authority response proposes a review of the DGAC airworthiness directive when issued. The Australian Transport Safety Bureau will continue to monitor that proposed action.

R20010197 issued on 18 September 2001

The Australian Transport Safety Bureau recommends that the Direction Generale de l'Aviation Civile take appropriate action to ensure the continued airworthiness of aircraft fitted with Turbomeca Arriel engines incorporating modification TU204.

Direction Generale de l'Aviation Civile response received on 15 January 2002:

"Taking into account the possible occurrence rate (probability calculation) of a double engine failure on twin engine helicopters and the fact it is no longer possible to install or repair blades modified by TU 204, there is no need to take a specific action for twin engine helicopters. However, as a conservative approach, DGAC will mandate by airworthiness directive the replacement of all these blades on single engine helicopters."

Australian Transport Safety Bureau response classification- MONITOR

The Direction Generale de l'Aviation Civile response proposes an airworthiness directive to address single engine variant helicopter engines only. The Australian Transport Safety Bureau will continue to monitor this proposed action.

Technical Analysis Report

Technical Analysis Report: Examination of Components from a Failed Turbomeca Arriel 1S1 Turboshaft Engine, Sikorsky S76 Helicopter, VH-EXX

1. FACTUAL INFORMATION

1.1 Introduction

A Sikorsky S76C helicopter (VH-EXX) sustained a failure of the number-two engine during cruise flight. The failed engine was a Turbomeca Arriel 1S1 turboshaft engine, serial number 15038 and had accumulated 7,935 hours and 6,784 cycles since new.

Reports from the flight crew indicated that the engine failure was associated with a loss of gas-generator turbine speed and an escalation of turbine outlet temperatures. Fire warnings for the engine were also received, prompting the pilot commanded shutdown of the engine and discharging of the fire suppression system.

1.2 Engine examination

Disassembly of the engine (figure 1) was carried out at the Bankstown (NSW) facility of Turbomeca Pty Ltd, in the presence of representatives from the engine manufacturer, the helicopter operator and the Australian Transport Safety Bureau. The examination revealed the following significant damage to the operating components of the engine:

  • Outer wall of the centrifugal diffuser cracked and separated into seven pieces over half the circumference (figure 2).
  • First-stage gas-generator turbine blades oxidised and burnt over the outermost third of their length (figure 3).
  • Second-stage nozzle guide vanes extensively overheated and partially melted on the convex (trailing) face and on the trailing edges (figure 4).
  • Second-stage gas-generator turbine blade number 16 fractured beneath the platform. Remaining blades burnt and mechanically damaged on tip edges (figure 5).
  • Second-stage NGV housing indented and punctured, circumferential cracking extending from this area (figure 6).
  • Power turbine NGV missing two vanes; the remainder showing mechanical damage (figure 7).
  • Number-three (rear) bearing collapsed, showing extensive overheating and out-of-balance damage to races and adjacent seals (figure 8).
  • Rear bearing air vent and oil return lines fractured from outside of housing (figure 9).
  • Two of the three T5 thermocouples burnt away completely (figure 10).

Figure 1. Arrial 1S1 engine, serial number 15038, as removed from the aircraft.

Arrial 1S1 engine, serial number 15038, as removed from the aircraft.

Figure 2. Diffuser assembly, showing break-up of the outer housing.

Diffuser assembly, showing break-up of the outer housing.
 

 Figure 3. First-stage gas-generator turbine blades oxidised and burnt over their outer length.

First-stage gas-generator turbine blades oxidised and burnt over their outer length.

 

Figure 4. Second-stage nozzle guide vanes extensively melted and disrupted in a localised area.

Second-stage nozzle guide vanes extensively melted and disrupted in a localised area.

Figure 5. Second-stage gas-generator turbine blades damaged and oxidised, with one blade missing. Item in upper left corner is a guide vane from the power turbine NGV.

Second-stage gas-generator turbine blades damaged and oxidised, with one blade missing. Item in upper left corner is a guide vane from the power turbine NGV.

Figure 6. Second-stage NGV housing with a large puncture and cracking from the released turbine blade.

Second-stage NGV housing with a large puncture and cracking from the released turbine blade.
 

Figure 7. Power turbine NGV assembly, missing a vane (see Figure 5).

Power turbine NGV assembly, missing a vane

Figure 8. Rear bearing race and rotating air seals, showing extensive out-of-balance damage.

Rear bearing race and rotating air seals, showing extensive out-of-balance damage.

Figure 9. Rear bearing air vent line, fractured at point of connection with the bearing housing. The oil return line had failed in a similar way.

Rear bearing air vent line, fractured at point of connection with the bearing housing. The oil return line had failed in a similar way.

Figure 10. Thermocouple assembly - thermocouples at arrows burned/damaged.

Thermocouple assembly - thermocouples at arrows burned/damaged.

From these observations, the axial compressor diffuser assembly and the second stage turbine rotor were selected for further examination.

Significant Factors

  1. The gas generator (GG) second-stage turbine blade incurred a fatigue fracture and separated.
  2. The engine manufacturer retained in service modified GG turbine blades, which from past experience could encounter unknown stress levels at the blade root. Those stresses could then possibly cause the blade to separate.

Analysis

Turbine blade separation

The failure mode of the gas generator (GG) rear bearing collapse was attributed to an imbalance condition of the GG second stage disc following the separation of a GG second stage turbine blade. That imbalance condition resulted in high vibration loads and damage to the rear bearing, resulting in module three failure. The damage to the centrifugal diffuser was determined to be a secondary failure and not considered a safety of flight concern.  

Modification TU204

During the period 6 September 1996 to 11 July 2001, there were five reported incidents worldwide of turbine blade separation failure possibly related to modification TU204. Of those five documented failures, all had modification TU204 incorporated. 

The engine manufacturer had identified a possible mass increase and resulting stress increase on the blade roots of turbine blades with the modification TU204 plasma coating applied. They addressed those concerns by discontinuing its incorporation and removing TU204 compliant blades from service during overhaul of number three modules. The recommendation by the manufacturer to remove all TU204 modified modules was not made a mandatory requirement by any airworthiness authority. Arriel 1S1 engine number three modules (and other Arriel variant engines with modification TU204 incorporated) that have not passed through an approved overhaul facility since July 1998 may currently have modification TU204 installed. Those engines and modules may be subject to abnormal blade loading stresses. The imminent separation of a turbine blade is not detectable by any on-board instrumentation or flight crew observations.

Engine fire

After activation by the crew, the engine compartment fire bottles successfully extinguished the fire that occurred following rear bearing collapse and subsequent fracture of the return oil pipe. The external oil pipes were exposed to the high vibration loads imposed by the out-of-balance GG turbine disc and, as a result, two fractured. Following the fracture of the return oil pipe, a heated flammable liquid (oil), was sprayed onto the heated external outer surface of module three. During normal operation, the outer surface of module three experienced surface temperatures within the auto-ignition range of the engine oil. The oil ignited causing an in-flight fire. The fuel source of the fire was the heated engine oil escaping from the fractured return oil pipe. The ignition source of the fire was the hot outer surface of module three. If the flight crew had not secured the engine, or the engine had not stopped rotating, the supply of flammables for combustion would have been limited only by engine oil system capacity.

Summary

The Sikorsky S76C helicopter was in cruise flight with the automatic flight control system engaged, when the flight crew noted a loud noise and the helicopter yawed to the left, rolled left, and the nose pitched down. The flight crew disengaged the automatic flight control system and resumed flying the helicopter manually, stabilising it in level flight. The right engine-out and fire-warning annunciators were illuminated, with the engine-out aural warning sounding. The right engine instruments displayed zero rotational speed of the gas generator (GG) and extremely high turbine outlet temperature (measured at point T4 within the engine). The crew activated the right engine fire bottles and simultaneously closed the fuel firewall shut-off valve. The fire indication extinguished. They then configured the helicopter for single engine flight with the remaining engine operating approximately ten seconds into the two and one-half minute One Engine Inoperative (OEI) limitation. The flight crew adjusted power requirements for the OEI condition and then completed an uneventful single engine landing at their Longford base.

Examination of the helicopter revealed minor shrapnel damage to the right engine exhaust extension, and fracture separation of the engine oil pressure switches and rear bearing external oil vent and return pipes.

The Turbomeca Arriel model 1S1 engine comprised five modules. Module three (or the high-pressure section) contained the gas generator first and second stage wheels. The left side of the right engine, forward of the external rear bearing oil return line near the outer surface of module three, displayed evidence of fire and oil residue.

The right engine was removed and shipped to the engine manufacturer's Australian facility for disassembly and examination with Australian Transport Safety Bureau (ATSB), operator, and engine manufacturer representatives in attendance.

Engine examination

Disassembly and preliminary examination of Arriel 1S1 engine, serial number 15038, revealed a separation of one GG second stage turbine blade. Blade number sixteen was separated above the blade 'fir tree' attachment point, below the blade platform, and had punctured the second stage nozzle guide vane turbine ring. The rear bearing of the GG had collapsed and was significantly damaged. Separated pieces of the centrifugal diffuser of module three were found inside the module. There were indications that several fracture surfaces of the separated sections were pre-existing before the incident. In addition, the engine exhibited signs of severe overheating and significant damage in the air path downstream of the turbine blade separation.

The fracture surface of the separated blade was typical of ductile tensile overload, with the exception of the small corner area of fatigue cracking. The dendritic patterns within the fracture were indicative of the normal underlying microstructure of the blade casting. Failure of the blade in that mostly ductile overload manner indicated exposure to a transient or sustained stress level above the ultimate strength of the blade material at its operating temperature. Refer to ATSB Technical Analysis Report 200103038 (BE/200100017) for further details.

Engine history

The engine was installed on 4 March 2000 and had accumulated 7,935.0 hours and 6,784.1 cycles since new. It had been overhauled on 12 February 1999, and had accumulated 1,992.0 hours time since overhaul (TSO) and 1,878.1 cycles since overhaul. The GG assembly second stage turbine disc, serial number DC3666YC, had been installed during the overhaul with zero hours and cycles accumulated. The turbine disc and blades were well within the life limit of 10,000 cycles established by the manufacturer. Arriel engine modification TU204 (GG turbine blade plasma coating) had been incorporated.

Previous Australian occurrences

Occurrence report 200100584

On 7 February 2001, a Sikorsky S76C helicopter belonging to the same operator, with two crew and ten passengers on-board, was in a hover with the flight crew completing before take-off checklist items. The pilot reported that while trimming the engines, a "pop" was heard. He then noted that the left engine turbine gas temperature (measured at point T4 within the engine) was in excess of 1000 degrees C. The helicopter was then landed uneventfully. The flight crew reported that the only cockpit indication of imminent failure was the almost simultaneous illumination of the left engine chip (magnetic particle) detector advisory.

Examination of the helicopter revealed minor shrapnel damage to the left engine exhaust extension and engine cowling. There was no reported engine fire. The left engine was removed and sent to the engine manufacturer for disassembly and examination. The manufacturer's final report noted a separation of turbine blade number six of the GG second stage disc. The blade was separated above the 'fir tree' attachment point but below the blade platform, and had punctured the second stage nozzle guide vane turbine ring. One adjacent blade (number seven) in the direction of turbine wheel rotation was also noted as cracked.

Metallurgical examination by the manufacturer attributed the blade failure to a low-cycle fatigue cracking mechanism. The manufacturer concluded that abnormal loading was the major contributing factor in the failure, given the reported absence of anomalous material features or evidence of high-temperature operation. Dimensional inspections failed to reveal any sign of non-conformity that could have led to the development of the abnormal loads. However, the manufacturer stated that turbine blade platform/GG disc interferences were also a potential factor that could have aggravated the fatigue failure of the blade.

At the time of the occurrence, Arriel 1S1 engine, serial number 15522, had accumulated 4,737.4 hours and 4,471 cycles since new. It had accumulated 1,740.0 hours TSO and 1,615 cycles since overhaul. Following overhaul, the engine was installed on March 11, 1999. Module three did not have turbine blade plasma coating modification TU204 incorporated.

Occurrence report 199602839

On 9 September 1996, a Sikorsky S76C helicopter belonging to the same operator, experienced an in-flight engine failure of the right engine while taking off from an oil platform. A loud noise was heard before the engine failure. The right engine was shut down and the crew completed an uneventful single engine return to the Longford base. There was no reported associated engine fire. The right engine was removed and sent to the manufacturer for disassembly examination.

At the time of the occurrence, Arriel 1S1 engine serial number 15513, had accumulated 2,282.0 hours and 1,949 cycles since new. The manufacturer provided the operator with a final report noting the rupture (separation) of one GG turbine blade with subsequent rear bearing damage and GG seizure. Their report stated that the separation was suspected to be the result of blade rubbing with the second stage nozzle guide vanes with no signs of fatigue or abnormal over temperature operation. Module three had turbine blade plasma coating modification TU204 incorporated.

Other overseas occurrences

The French airworthiness authority, Direction Generale de l'Aviation Civile (DGAC), reported knowledge of three other overseas occurrences involving GG second stage turbine blade separation failures. Of those three incident engines, all had the TU204 modification. Cycles since overhaul on those incident engine turbine discs and blades varied from 1,978 to 5,933 cycles.

Engine service bulletin history

Turbomeca Service Bulletin (SB) 292 72 0151 was originally issued on 5 June 1992 specifying the incorporation of modification TU204, the protection of the GG second stage turbine blades from corrosion or erosion with a Heurchrome low pressure plasma coating. That modification also permitted a performance improvement by allowing the more accurate machining of the turbine tip diameter to control the tip clearance. The service bulletin addressed all Arriel variants, with Arriel 1S1 engines having incorporated TU204 from the first production engine. For all other variants, TU204 implementation was optional and installed at the customers' request.

In July 1998, the engine manufacturer implemented internal documentation and procedures to remove all GG turbine blades with TU204 installed during overhaul of module three. Consequently, SB 292 72 0151 was amended on 18 August 2000, to recommend removal of all TU204 modified blades, citing possible weight mass increases and suspected increased stress on the turbine blade root. The manufacturer stated that if the plasma coating was not applied as per drawing requirements, the resulting stresses could be more than anticipated, resulting in abnormal loading of the blade root. Both incorporation and removal of modification TU204 required removal of the engine and/or module and shipment to the manufacturer.

External oil pipe description

Three external oil related pipes provided lubrication of the GG rear bearing. Those pipes passed through hollow support struts and were then physically secured to module three. The supply oil pipe provided oil from the engine driven gear type oil pump to the bearing after passing through a restrictor and a tube screwed into the bearing housing. Oil was then sprayed onto the bearing. After lubricating the bearing, the oil fell by gravity to the bottom of the housing, through a tube and was returned to the tank through an oil pipe to the scavenge pump. The air/oil mist that resulted from the lubrication of the bearing was vented overboard through a vent pipe attached to the top of the housing.

Engine oil flashpoint/autoignition

The engine oil temperature of a normally operating Arriel 1S1 engine in a S76C helicopter was approximately 100 degrees Celsius (C). The flash point of the turbine engine oil was approximately 223 degrees C. The flash point of a liquid was defined as the lowest temperature at which a material would produce a flammable vapour, and was a measure of the volatility of the material.

The auto-ignition temperature of engine oil was approximately 388 degrees C. Auto-ignition temperature was defined as the temperature at which auto-igniting materials spontaneously combust. According to the engine manufacturer, during normal operation, the external surface temperatures of number three modules ranged between 280 to 450 degrees C, dependent upon location on the module, with a maximum surface temperature of 450 degrees nearest the rear bearing. The surface temperature maximum values of module three were well within the auto-ignition temperature of the engine oil.

Occurrence summary

Investigation number 200103038
Occurrence date 11/07/2001
Location 83 km E Longford, (HLS)
State Tasmania
Report release date 14/06/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Serious Incident
Highest injury level None

Aircraft details

Manufacturer Sikorsky Aircraft
Model S-76
Registration VH-EXX
Serial number 760435
Sector Helicopter
Operation type Business
Departure point Fortescue Platform, VIC
Destination Longford, VIC
Damage Minor

Mooney M20J, VH-UDD

Safety Action

Local safety actions

The ERSA was amended to advise frequency management instructions for crews entering Tamworth class "C" and "D" airspace from adjacent class "G" airspace.

During the course of this investigation Airservices Australia approved the installation of a tower situational awareness display (TSAD) in Tamworth Tower. The TSAD will display transponder equipped aircraft, within radar coverage, operating in the Tamworth control area and CTR. The TSAD is expected to be installed in July 2002.

Additionally, Airservices Australia has commenced a review of airspace boundaries on map displays with a view to reducing possible misinterpretation.

Significant Factors

  1. The Mooney pilot did not comply with AIP procedures.



 

Analysis

The pilot of the Mooney was an IFR pilot who should have been able to establish, from the information available, that Tamworth control area was class "C" airspace above 4,500 ft. He should also have known that he required an airways clearance prior to entering class "C" airspace. Had the pilot requested a clearance on any of the frequencies referred to in the ERSA or depicted on the charts, he would have been provided with the correct Tamworth ATC frequency on which to establish two-way radio contact and obtain an airways clearance. Two-way radio contact between Tamworth ATC and the pilot of the Mooney would have enabled Tamworth ATC to apply separation standards in accordance with MATS.

The relevant AIP's did not specify the vertical boundary between Tamworth control area and the overlying Brisbane sector. That omission may have made it difficult for the Mooney pilot to determine the correct ATC frequency on which to establish two-way radio contact with Tamworth ATC.

The Brisbane sector controller did not provide traffic information to Tamworth ATC about the Mooney because he had no reason to suspect that the Mooney was in Tamworth controlled airspace without an airways clearance. Provision of facilities that would have enabled Tamworth ATC to better determine the disposition of aircraft within and around Tamworth controlled airspace may have assisted Tamworth ATC to provide a separation standard between the Mooney and the Saab.

Summary

A Saab SF340B aircraft (Saab) departed Tamworth aerodrome and was tracking to the southeast on climb to flight level (FL) 120. A Mooney Aircraft Corporation M20J (Mooney) was travelling in the opposite direction en route from Bankstown to Inverell via Scone and Tamworth at 8,500 ft. The Mooney was in Tamworth class "C" controlled airspace. The Saab crew received a traffic alert from that aircraft's traffic alert and collision avoidance system as the Saab was approaching 8,000 ft. The Saab crew levelled their aircraft at 8,200 ft and rolled the aircraft to the left to avoid the Mooney. The pilot of the Mooney did not request or obtain an airways clearance from the Tamworth Aerodrome Controller (ADC) to enter Tamworth control area prior to the occurrence. The Saab passed within 1.8 nautical miles (NM) horizontally and 300 ft vertically of the Mooney. The required separation standard was either 1,000 ft vertically or a minimum horizontal distance determined using the appropriate "Lateral Separation" table in the Manual of Air Traffic Services (MATS). There was an infringement of separation standards.

Tamworth Air Traffic Control (ATC) provided a non-radar, or procedural control, service to aircraft operating within the Tamworth control area and control zone (CTR). Controllers used non-radar information to establish and maintain procedural separation standards in accordance with MATS. Tamworth class "C" control area steps extended to 36NM when above 6,500 ft AMSL to the south-southeast of the Tamworth aerodrome in the area that encompassed the flight path of the Mooney. Class "G" non-controlled airspace surrounded the Tamworth CTR and control area.

The Saab crew was conducting a scheduled fare-paying passenger flight under instrument flight rules (IFR) and had been cleared by the Tamworth ADC to climb to FL120. The standard altitude Tamworth ATC could assign to aircraft leaving Tamworth control area and entering the overlying Brisbane sector in accordance with the letter of agreement between Tamworth ATC and Brisbane ATC, was FL120 (subject to other aircraft). Otherwise, a procedural separation standard was applied by Tamworth ATC and coordinated with the Brisbane sector controller, or responsibility for separation was specifically assigned to the Brisbane sector controller.

The pilot of the Mooney was an IFR pilot and was normally provided with radio frequency management instructions by ATC along the route. On this flight however, the pilot of the Mooney was operating under visual flight rules (VFR) and no such advice was provided. All aircraft crews that planned to enter class "C" controlled airspace, whether operating under IFR or VFR, were required to establish two-way radio contact with ATC and obtain an airways clearance prior to entering class "C" airspace. The Tamworth visual terminal chart (VTC) depicted the lateral boundaries of class "C" control area surrounding Tamworth aerodrome above 4,500ft AMSL. However, neither the VTC nor the Aeronautical Information Publication (AIP) En-Route Supplement Australia (ERSA) specified the vertical boundary between Tamworth control area and the overlying Brisbane sector. The pilot later reported that he had studied the Jeppessen low altitude en-route chart relevant to Tamworth, prior to the flight, and believed that he would not require an ATC clearance to enter Tamworth control area above 6,500ft AMSL.

Airservices Australia reported that the Brisbane sector controller had seen the occurrence on that controller's air situation display (ASD) in the Brisbane Air Traffic Services Centre and had received a short term conflict alert (STCA) from The Australian Advanced Air Traffic System (TAAATS). The Brisbane sector controller reported that STCA's between aircraft operating within Tamworth control area were common but did not necessarily indicate a potential infringement of separation standards. Short term conflict alerts, in those circumstances, occurred when the procedural separation standard being used by Tamworth ATC was less restrictive than the STCA activation parameters used in TAAATS.

Although the track symbol and a label, showing the secondary surveillance radar code and the altitude from the Mooney, were displayed to the Brisbane sector controller on the ASD, the Brisbane sector controller had no control or jurisdiction over the Mooney and was not aware that the pilot had not established two-way radio contact with Tamworth ATC. The Brisbane sector controller was also not aware that the pilot had not received an airways clearance to enter Tamworth control area. The Brisbane sector controller believed both aircraft were under the control of Tamworth ATC because both aircraft were within the Tamworth control area. The Tamworth ADC was unable to provide a separation service to the Saab in relation to the Mooney as he had no information on that aircraft.

Occurrence summary

Investigation number 200102905
Occurrence date 05/07/2001
Location 12 km SSE Tamworth, (VOR)
State New South Wales
Report release date 15/07/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Mooney Aircraft Corp
Model M20
Registration VH-UDD
Serial number 24-0272
Sector Piston
Operation type Private
Departure point Bankstown, NSW
Destination Inverell, NSW
Damage Nil

Aircraft details

Manufacturer Saab Aircraft Co.
Model 340
Registration VH-LIH
Serial number 316
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Tamworth, NSW
Destination Sydney, NSW
Damage Nil

Beech Aircraft Corp 1900D, VH-IMS

Safety Action

Local safety action

As at 24 June 2002, Airservices Australia had installed a tower situational awareness display (TSAD) in the equipment room in the Tamworth control tower complex so that appropriate maps can be loaded and system performance monitored. Airservices Australia expects to install the TSAD in the Tamworth control tower cabin in September 2002. Although the TSAD is not used to apply separation standards between aircraft, it should (when operational) assist controllers with situational awareness in this complex air traffic environment.

In an effort to control training in Tamworth controlled airspace, the Tamworth ERSA entry, effective 13 June 2002, now requires pilots planning instrument training at Tamworth, during tower hours, to obtain approval from Tamworth ATC prior to submission of the flight plan.

Analysis

Although the crew was operating a regular public transport operation, the cockpit of the B1900 was a training environment and the Tamworth airspace was busy at the time of the occurrence. This led to a complex and dynamic situation in which the crew of the B1900 chose to continue descent, even though they were unable to comply with the circuit entry instruction. Had the B1900 remained at 4,000 ft until the crew could advise the ADC 1 that they could not track as instructed, the aircraft would have remained vertically separated with the traffic entering, and operating in, the southern circuit. That would also have provided the controller with time to evaluate the situation and issue alternative instructions.

The crew reported that they were unable to advise the ADC 1 that they could not comply with the circuit entry instruction due to frequency congestion. However, they had an opportunity to inform the controller when they acknowledged the clearance for the visual approach.

The controller believed that there had not been an infringement of separation standards between the B1900 and traffic inbound to the southern circuit. However, no standard had been established once the B1900 had left 4,000 ft on descent. The controllers did not have enough time to sight the inbound CT4s and apply visual separation because they expected the crew of the B1900 to comply with the clearance as acknowledged. Consequently, visual separation could not be applied because the ADC 2 had not sighted the inbound aircraft and no other procedural separation standard, in accordance with MATS, had been established between the B1900 and the inbound aircraft.

Summary

The crew of the Beech 1900D (B1900) aircraft had been cleared by the aerodrome controller (ADC) 1 to descend to 4,000 ft and were instructed to join the circuit via a left base leg for runway 12L (northern) circuit at Tamworth. The ADC 1 also instructed the crew to report approaching 4,000 ft. The crew acknowledged the clearance but later advised that they were unable to report approaching 4,000 ft due to frequency congestion. The ADC 1 had assigned 4,000 ft so that a procedural separation standard of 1,000 ft could be maintained with other aircraft until he could see the B1900 and apply visual separation.

The crew of the B1900 subsequently requested confirmation of their assigned level and reported their position when at 2NM north of the aerodrome. The controller then sighted the aircraft and cleared the crew to make a visual approach. The controller also asked the crew if they would need to extend through the centreline of runway 12L. The crew acknowledged the visual approach but did not advise the controller that they would need to extend through the centreline. The visual approach clearance authorised the crew to descend below 4,000 ft.

The crew of the B1900 could not comply with the instruction to join the circuit via a left base for runway 12L because the aircraft was too high and too fast. The co-pilot was the non-flying pilot and was undergoing command upgrade training. He had acknowledged the clearance for the visual approach and had previously acknowledged the instruction to join the northern circuit via a left base leg for runway 12L. At the time that the visual approach clearance was issued, the pilot-in-command was aware that they could not comply with the circuit entry instruction. He believed that the controller would have been aware that they were unable to enter the circuit on a left base leg, given their proximity to the circuit at that time and the height and speed of the aircraft. He also believed that the controller would have taken those circumstances, and the disposition of traffic in the southern circuit, into account when issuing the visual approach instruction.

The B1900 continued to descend and entered the runway 12R (southern) circuit airspace which was under the control of the ADC 2. The ADC 1 notified the ADC 2 that the B1900 had entered the southern circuit. The ADC 2 advised the ADC 1 that there was a Pacific Aerospace Corporation Airtrainer CT4B (CT4) on a right base leg for runway 12R. The ADC 2 provided traffic information about the B1900 to the crew of the CT4. There were four other CT4 aircraft inbound to the circuit at that time but the ADC 2 had not sighted them. The ADC 1 was unable to apply the required separation standard, either 1,000 ft vertically, or a minimum horizontal distance determined using the appropriate `Lateral Separation' standard from the Manual of Air Traffic Services (MATS), between the B1900 and the traffic inbound to the southern circuit. There was an infringement of separation standards.

The ADC 1 reported that he had sighted the CT4 on right base. He then instructed the crew of the B1900 to make a right turn and track via a right base leg for runway 12L. He believed that the B1900 was visually separated from that CT4 and that he could maintain visual separation between the B1900 and that CT4 with that instruction. He did not think that there had been an infringement of separation standards between the B1900 and the aircraft inbound to the southern circuit because all parties had enough time to ensure that visual separation was not infringed.

Occurrence summary

Investigation number 200102901
Occurrence date 27/06/2001
Location 4 km N Tamworth, Aero.
State New South Wales
Report release date 16/09/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Beech Aircraft Corp
Model 1900
Registration VH-IMS
Serial number UE-214
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Glen Innes, NSW
Destination Tamworth, NSW
Damage Nil

Aircraft details

Manufacturer Pacific Aerospace Corporation
Model CT4B
Sector Piston
Departure point Tamworth, NSW
Destination Tamworth, NSW
Damage Nil

de Havilland Canada DHC-8-102, VH-XFT

Safety Action

Local safety action

As a result of this investigation, Airservices Australia provided the Australian Transport Safety Bureau with the following response. `The information you provided with respect to the application of visual separation as per MATS 4.5.1.11 was discussed with some and forwarded to all Business Unit procedures specialists for appropriate action. Additionally, it was forwarded to local QA areas and DSEA audit for follow up ensuring the ongoing correct application of this procedure'.

Summary

A Boeing 747-200 (B747) was being radar vectored from the west for sequencing to runway 21 at Perth. A de Havilland Canada DHC-8-102 (Dash 8) was being radar vectored from the east for sequencing to land on runway 21 behind the B747. When the crew of the Dash 8 reported that they had sighted the B747, the air traffic controller assigned them the responsibility for separation from the B747. The rate of closure between the two aircraft was high and the crew of the Dash 8 received a traffic advisory from their traffic alerting and collision avoidance system. Although the Dash 8 crew was being issued with radar vectoring instructions by air traffic control, they were obliged to turn their aircraft to the right to avoid the B747.

Radar data and air traffic control automatic voice recordings were reviewed to establish the sequence of events. The investigation found that the approach controller had assigned the responsibility for separation to the pilot of the arriving Dash 8 while the aircraft was being radar controlled. The radar separation standard required 3NM horizontal separation while there was less than 1,000ft of vertical separation. During the occurrence, radar separation reduced to 1.82NM when there was 100ft vertical separation. A radar or vertical separation standard was not required when some other form of separation was being applied. In this situation the controller was relying on visual separation.

Visual separation of air traffic may have been a valid method to use in circumstances where less than the required radar separation is achievable. However, the criteria for the application of the standard were clearly detailed in the Manual of Air Traffic Services (MATS) Part 4 Section 5. In particular, MATS 4.5.1.11 stated:`In circumstances where an aircraft has been instructed to maintain separation from, but not follow, an IFR aircraft, traffic information shall be issued to the IFR aircraft, including advice that responsibility for separation has been assigned to the other aircraft'. The arriving B747 was an IFR aircraft but was not provided with the required traffic information.

Occurrence summary

Investigation number 200102866
Occurrence date 25/06/2001
Location 15 km NNE Perth, (VOR)
State Western Australia
Report release date 18/07/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category ACAS warning
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer De Havilland Canada/De Havilland Aircraft of Canada
Model DHC-8
Registration VH-XFT
Serial number 052
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Plutonic Mine, WA
Destination Perth, WA
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration ZS-SAL
Sector Jet
Operation type Air Transport High Capacity
Departure point Johannesberg, SOUTH AFRICA
Destination Perth, WA
Damage Nil

Embraer EMB-110P1, VH-OZG

Summary

On 25 June 2001, an Embraer Bandeirante on a charter flight from Sydney to Griffith, sustained an in-flight engine fire during cruise. The pilot attempted to extinguish the fire, and believing it to be extinguished, commenced a rapid descent to Young. Fog at Young prevented a landing, and the pilot diverted the aircraft to Cootamundra. Smoke entered the cabin, and the pilot transmitted a MAYDAY. Only the right main landing gear extended when the landing gear was selected down, but the pilot did not get an indication of the landing gear position. Unaware that the right main landing gear had extended, he prepared to make a gear-up landing. The aircraft touched down on the right main wheel and settled onto the left engine nacelle and nose, sustaining abrasion damage as it slid along the runway. The fire in the right engine nacelle was still burning when the aircraft stopped. The occupants egressed uninjured, and bystanders extinguished the fire.

Technical investigation revealed that vibration from the worn armature shaft of the right engine starter generator initiated a fatigue crack in the fuel return line. Fuel leaked from the fractured line during the flight, and was ignited by sparks or frictional heat from the generator after the armature shaft failed.

The pilot reported that he was unable to select the fuel cut-off position with the right fuel condition lever and feather the right propeller. While carrying out the engine fire emergency checklist actions, the pilot did not complete all of the items of the manufacturer's engine fire emergency checklist and the firewall shut-off valve remained open. Fuel continued to flow to the fuel control unit and feed the fire. The investigation was unable to determine if the fire extinguisher bottle discharged effectively. The fire continued to burn and heat conducted through the firewall affected components in the wheel well. Smoke from the heat-damaged components entered the aircraft cabin though gaps between the wing root and fuselage.

Checklists carried on the aircraft did not contain appropriate smoke evacuation procedures and the pilot's attempts to evacuate smoke from the cabin were unsuccessful. Consequently, the uncontained fire in the engine nacelle, and smoke in the cabin, created a potentially life threatening situation and influenced the pilot's decision not to delay the landing while attempting to resolve the apparent failure of the landing gear to extend.

This occurrence demonstrates the need for error-free and complete checklists to be available to pilots during emergency situations. It also demonstrates the need for pilots to be familiar with the systems of the aircraft they operate, and the emergency actions to be taken in the event of abnormal or emergency situations. Regular practice of those procedures is essential if they are to be executed effectively. More thorough training and checking of (charter) pilots, as proposed in the Civil Aviation Safety Regulations Part 121B (charter) operations, if adopted, can potentially improve pilot proficiency and knowledge in emergencies, specific to the aircraft type.

As a result of this occurrence the ATSB recommended to the Civil Aviation Safety Authority, the aircraft manufacturer and the certification authorities that the temperature setting of thermal relief valves on fire bottles, and the temperature setting of fire detectors, be reviewed to avoid inadvertent discharge of fire bottles. The ATSB also recommended that crews be provided with an indication of fire bottle contents.

Occurrence summary

Investigation number 200102710
Occurrence date 25/06/2001
Location Cootamundra, Aero.
State New South Wales
Report release date 06/11/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Smoke
Occurrence class Accident
Highest injury level None

Aircraft details

Manufacturer Embraer-Empresa Brasileira De Aeronautica
Model EMB-110
Registration VH-OZG
Sector Turboprop
Operation type Charter
Departure point Sydney, NSW
Destination Griffith, NSW
Damage Substantial

Fairchild SA227-AC, VH-UUN

Summary

The Metroliner III was departing Cooktown for Cairns. At about 250 ft above ground level the flight crew noticed that a fuel by-pass light had illuminated. The crew reported that they then retarded both engine power levers slightly in an attempt to extinguish the light. The left engine torque indications immediately began to fluctuate by about 5 percent but then increased to 20 percent. The left exhaust gas temperature and fuel flows were also fluctuating. The engine torque indications continued to surge, and the pilot-in-command elected to shut down the engine as a precautionary measure. The crew then notified air traffic control of their intention to return to the departure runway, where the aircraft made a single engine landing.

Subsequent trouble shooting determined that the engine problem was associated with a transient fault in the Single Red Line computer for the left engine. The computer was replaced, and the aircraft was returned to service without recurrence.

The company safety officer reported that he conducted an investigation into the incident and advised that, as the aircraft performance was not significantly impaired and because there was no indication of fire or catastrophic failure, it would have been more appropriate for the crew to continue the climb with both engines operating until a more detailed assessment of the situation could be made.

The occurrence brief is based on information obtained from the company's safety officer. The ATSB did not conduct an on-site investigation into the occurrence.

Occurrence summary

Investigation number 200102697
Occurrence date 18/06/2001
Location Cooktown, Aero.
State Queensland
Report release date 25/09/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Abnormal engine indications
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Fairchild Industries Inc
Model SA227
Registration VH-UUN
Serial number AC-686
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Cooktown, QLD
Destination Cairns, QLD
Damage Nil

Boeing 737-476, VH-TJY, on 18 June 2001

Summary

As the Boeing 737-476 (B737) operating a scheduled passenger service to Adelaide, accelerated during the take-off roll on runway 06 at Perth International Airport, the driver of a sweeper vehicle operating on that runway saw the aircraft approaching in the vehicle's rear-view mirror, turned right and vacated the runway. The crew of the B737 saw the vehicle vacating the runway and continued with the take-off.

Occurrence summary

Investigation number 200102695
Occurrence date 18/06/2001
Location Perth, Aero.
State Western Australia
Report release date 27/09/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Serious Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 737
Registration VH-TJY
Serial number 28151
Sector Jet
Operation type Air Transport High Capacity
Departure point Perth, WA
Destination Adelaide, SA
Damage Nil

Cessna 402B, VH-FFJ

Safety Action

Local safety action

Airservices Australia addressed a number of procedural issues identified during their investigation of the occurrence.

Analysis

It is likely that the pilot was under some self-imposed stress due to the need to ensure that the passengers connected with their next flight. The level of stress probably increased as he attempted to prepare for the arrival and landing at Sydney. Consequently, when he saw what he believed to be the parallel runways he readily accepted that the taxiway was runway 16R despite the significant lateral distances between the parallel runways and also between their respective thresholds.

Confirmation bias occurs when people search for information to confirm what they suspect. People rarely attempt to prove themselves wrong and often disregard information that may contradict their perception of a situation. Despite the pilot referring to an aerodrome diagram, and the lack of runway markings on the selected `runway', he did not comprehend that he was approaching taxiway Alpha instead of runway 16R. It is possible that the pilot's perception, that he had correctly identified runway 16R, was reinforced by the change in contrast of the taxiway surface near the northern end of taxiway Alpha. He may also have been lulled into thinking that the approach was normal, despite the minimal markings on the selected landing area, because of his past experience with runways with little or no markings.

Following the go around, there was an opportunity for the error to be recognised if the pilot had advised the aerodrome controller that an aircraft entered the runway during his approach. Such a comment probably would have caused the controller to query the pilot regarding the runway he had approached. However, during the subsequent go around the pilot had little time to query the aerodrome controller before changing frequency. While being resequenced for the second approach, there was an opportunity for the pilot to query the departure or director controller about the potential hazard he had just experienced. It would have been prudent of the pilot to highlight the situation to at least one of the controllers. The integrity of the aviation system is contingent upon all those involved advising concerns or clarifying situations to maintain safety.

Without an ILS the pilot had limited means, other than ATC, to assist him to confirm that he had positioned the aircraft on the extended centerline for runway 16R.

While the director controller was required to obtain a report from the pilot of having the runway in sight, the provision of that report would not necessarily have prevented the occurrence. The lateral proximity of runway 16R and taxiway Alpha meant that even if the pilot had reported the runway in sight he might still have mistaken taxiway Alpha for the runway. Also, the proximity of the runway and taxiway made it unlikely that the aerodrome controller could differentiate, using radar or visual means, between an aircraft approaching the taxiway or the runway.

During the second approach, the pilot had no external cues to question his misidentification of the runway on the initial approach, and thus positioned the aircraft for a landing on taxiway Alpha. Although he was advised that he was following an aircraft for the same runway, it is apparent that this advice was not sufficient for him to review the situation. It is likely that his focus did not extend beyond flying the final approach and preparing for the landing.

The occurrence highlights the need for adequate pre-flight preparation and for pilots to utilise available resources. Had the pilot had more time, it is likely that he would have been better prepared for the approach and landing to an unfamiliar aerodrome. Additional time may also have provided an opportunity for the pilot to consider other resources that were available. In this respect, he may have considered advising the controllers that it was his first time into Sydney, or immediately notified them of the perceived runway infringement. Either action would probably have provided additional information to assist in his subsequent decision making while operating in what was essentially (for the pilot) a foreign environment.

Summary

The pilot of the Cessna 402 (Cessna) had been cleared by the aerodrome controller (ADC) to land on runway 16R at Sydney Kingsford Smith airport. The ADC monitored the aircraft's approach and after landing it was established that the pilot had landed on taxiway Alpha, which was parallel to, and to the right, of runway 16R. There was no other aircraft on taxiway Alpha at the time. The weather was visual meteorological conditions (VMC).

The pilot of the Cessna had approximately 3,000 hours flying experience and had planned to operate an instrument flight rules (IFR) charter flight from Broken Hill to Bankstown via Dubbo. En route the pilot amended the destination to Sydney in an attempt to assist the passengers to connect with their next flight. The pilot had never operated into Sydney but had recently operated into Adelaide and felt that he could self-brief satisfactorily using the Aeronautical Information Publication (AIP) documents. He was familiar with Bankstown but predominantly operated in country areas where, generally, runways had limited or no markings.

Runway 16L was 2483 m long and runway 16R was 3962 m long. Each runway had a parallel taxiway located to the right. Runway 16L was 1037 m to the left of runway 16R and taxiway Alpha was 183 m to the right of runway 16R. Runway 16R threshold was 2,862 m north of the runway 16L threshold. Runway 16R threshold was 497 m north of the intersection of taxiways Alpha and Foxtrot. The colour of the surface of taxiway Alpha changed between taxiways Foxtrot and Golf due to a bitumen/concrete join.

The flight departed Dubbo at 1445 Eastern Standard Time. The pilot tracked via Bindook and was issued with an Odale 2 standard arrival clearance to the aerodrome. He was using the AIP En Route Supplement to assist in orientating himself with the aerodrome layout and made a visual approach to final for runway 16R. He reported that when the aircraft was on the [right] base position he had an uninterrupted view of the area and could see what appeared to be the parallel runways. At the time, the pilot did not appreciate the distance between the runways and the extent of the offset of the runway thresholds. He aligned the aircraft with what he thought was runway 16R, but in fact was taxiway Alpha, with the intention of landing. The ADC issued a landing clearance and as the aircraft passed 1,500 ft on descent the pilot saw a Boeing 747 enter the taxiway he had intended to use. The pilot elected to go around and advised the ADC that he was initiating a go around. The ADC coordinated a clearance with the departure controller and instructed the pilot to turn onto a heading of 170 degrees, to climb to 3,000 ft and to contact the departure controller. The pilot did not query the ADC with respect to the aircraft entering his intended runway as he immediately complied with the instructions and changed to the departure radio frequency.

The ADC saw that the Cessna was high on final and believed that the pilot conducted the go around because the aircraft was too high and did not query the pilot about the approach. The prime means for the ADC to establish aircraft positions was by monitoring aircraft visually. The ADC had an air situation display (ASD), plus access to a surface movement radar (SMR) display to assist in confirming positions of arriving and departing aircraft, and aircraft on the aerodrome. The resolution of both displays was dependent on the selected scale and was also limited, to some extent, by the lateral proximity of runway 16R and taxiway Alpha.

The aircraft was re-sequenced for another visual approach to runway 16R. During the second approach the pilot again aligned the aircraft with what he believed to be runway 16R and subsequently landed on taxiway Alpha.

Runway 16R and taxiway Alpha were marked in accordance with Civil Aviation Safety Authority Rules and Practices for Aerodromes.

Taxiway Alpha had:

  1. centreline markings, and
  2. sideline markings.

Runway 16 had:

  1. threshold markings,
  2. designation or number (16R) markings,
  3. centreline and sideline markings,
  4. fixed distance markings, and
  5. touchdown zone markings.

Runway 16R was served by an instrument landing system (ILS) navigation aid which provided centerline and glidepath guidance to pilots of aircraft that were fitted with ILS avionics. It also had a T-VASIS that provided a visual approach slope indication. The Cessna was not fitted with an ILS and the pilot was not qualified to conduct an ILS approach. The pilot was instructed by the director controller to report the runway in sight. The pilot reported he had the "aerodrome in sight". The controller did not subsequently query the pilot to confirm that he had the runway in sight. The requirement to report the runway in sight was a function of independent visual approach procedures and was not a runway allocation procedure.

During the second approach, the distance between the Cessna and an aircraft ahead in the approach sequence was reducing and was likely to infringe the required wake turbulence separation standard of 6 NM. The director asked the pilot if he was happy to continue the approach with less than the standard separation. The pilot reported to the director that he was happy to continue. Manual of Air Traffic Services (MATS) procedures required controllers to "ensure that the appropriate wake turbulence minima are applied at the landing threshold" for aircraft on final approach to the same runway. The intention was for only pilots to initiate requests for wake turbulence waivers. Controllers were not to initiate such requests.

Occurrence summary

Investigation number 200102619
Occurrence date 31/05/2001
Location Sydney, Aero.
State New South Wales
Report release date 21/01/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Depart/app/land wrong runway
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Cessna Aircraft Company
Model 402
Registration VH-FFJ
Serial number 402B1016
Sector Piston
Operation type Charter
Departure point Dubbo, NSW
Destination Bankstown, NSW
Damage Nil