Bankstown midair collision, Piper PA-28-161, VH-IBK, SOCATA TB-9, VH-JTV, 5 May 2002

Executive summary

Report release date: 04/05/2004

At about 1525:34 Eastern Standard Time (EST) on 5 May 2002, a Piper PA-28-161 aircraft, registered VH-IBK, and a Socata TB-9 aircraft, registered VH-JTV, collided on final approach to Bankstown airport, New South Wales. General Aviation Airport Procedures (GAAP) were in operation at the time, and aircraft were using simultaneous contra-rotating circuits onto parallel runways (contra-circuits) in the 29 direction. Under GAAP, pilots operating in visual meteorological conditions were responsible for aircraft separation when airborne in the circuit. Air traffic controllers were responsible for providing sequencing, traffic information to pilots, and runway separation.

The pilot of IBK had been issued with a clearance to land on runway 29 Centre (29C) from a right circuit by the aerodrome controller one (ADC1). The pilots of JTV had been issued with a clearance to conduct a touch and go landing on runway 29 Left (29L) from a left circuit by the aerodrome controller two (ADC2). The ADC1 provided traffic information to the pilot of IBK, but had not informed ADC2 that IBK was using runway 29C. Consequently, ADC2 was not aware that IBK was using runway 29C and did not provide traffic information to the pilots of JTV. This omission was not considered to be a factor in the accident as the pilots of JTV saw IBK on the base leg. The pilot of IBK reported to ADC1 that he had sighted the traffic, but the investigation was unable to determine whether he saw JTV or VH-SVK, which was following JTV in the southern circuit.

The two aircraft collided on, or near, the extended centreline of runway 29L about 1,700 m from the runway threshold. The collision occurred as IBK crossed the extended centreline of runway 29L on a heading about 25 degrees to the left of the extended runway centreline. At the time of the collision, JTV was probably aligned with the extended centreline of runway 29L. None of the three controllers on duty in Bankstown tower at the time observed the accident, nor were they required to be monitoring the position of IBK and JTV at the time.

The collision resulted in damage to the left stabilator and the separation of the vertical stabiliser of IBK, which resulted in the aircraft becoming uncontrollable. IBK subsequently impacted the ground in an industrial area to the southeast of the airport and the four occupants were fatally injured. There was no fire. Impact forces destroyed the aircraft. Following the collision, the instructor pilot landed JTV safely on runway 29L at Bankstown and the two occupants were uninjured.

There was no evidence that fuel contamination, mechanical malfunction, structural failure, a birdstrike, or meteorological conditions were factors in the occurrence.

The distance between the centrelines of runway 29C and runway 29L was 107 m. In 1979, the standard for contra-circuit operations at GAAP airports was specified as a minimum distance of 213 m between runway centrelines. The aviation safety regulator subsequently granted a concession to permit GAAP operations at Bankstown on to runways with a minimum separation of 107 m between centrelines. This concession was intended to be a short-term measure until the completion of runway upgrading work, which occurred in the mid-1980s. The regulator changed the 213 m standard to a recommended practice in 1989.

A significant proportion of GAAP operations at Bankstown involved contra-circuit operations onto parallel runways 107 m apart, with about 12 per cent of all arriving aircraft (or about 30 per cent of arriving aircraft from the northern circuit) landing on runway 11C/29C. At the same time that these aircraft were landing on runway 11C/29C, there were generally multiple aircraft operating in the southern circuit and landing on runway 11R/29L. The use of runway 11C/29C had probably increased during the period since the implementation of GAAP at Bankstown in 1980.

There was no operational requirement for the pilot of IBK to use the centre runway. However, it was common practice for pilots of aircraft based on the southern side of the airport to make such requests on arrival into the circuit to minimise taxi time. It was also common practice for Bankstown controllers to approve such requests during contra-circuit operations.

The critical event leading to the midair collision was IBK passing through the extended centreline of runway 29C into the flight path of JTV at or about the centreline for runway 29L. The investigation estimated that IBK passed through the runway 29C centreline at about 1525:29, 5 seconds prior to the collision. The reason why IBK passed through the extended centreline of runway 29C could not be determined.

The investigation concluded that there were insufficient visual cues available for a pilot in one circuit to reliably assess the collision potential of an aircraft in the opposing circuit when both aircraft were conducting contra-circuit operations to parallel runways that were 107 m apart.

The primary mitigator in place at Bankstown to prevent a collision involving two aircraft conducting contra-circuits to runways 107 m apart was the provision by controllers of traffic information to the pilots. Research has indicated that the provision of traffic information will increase the probability of a pilot detecting another aircraft. However, for the opposite-base traffic situation, there was insufficient evidence to determine the extent of the mitigator's influence on collision risk.

The accident was the first mid-air collision at Bankstown since 1975. However, the investigation considered that the estimated risk level for midair collisions at Bankstown probably exceeded the scrutiny line of the Civil Aviation Safety Authority's acceptable risk criteria. For a general aviation airport such as Bankstown, this meant the risk levels were at the upper end of the 'as low as reasonably practical' region. This situation placed an onus on those agencies responsible for managing the risk at Bankstown to ensure that appropriate risk management processes were in place. The air traffic service provider, Airservices Australia, had implemented a safety management system, but at the time of the accident there were limitations in the processes for identifying and monitoring hazards at major general aviation airports such as Bankstown.

In late 2000 Airservices decided to prepare risk management plans for all control towers throughout Australia, including Bankstown. There was no regulatory requirement for these plans. The risk management plan for Bankstown Tower was commenced in January 2003 and completed in February 2003. In December 2003, Airservices modified its procedures for Bankstown so that, where aircraft involved in contra-circuits were likely to be at base or final legs at approximately the same time, the use of the centre runway would be denied.

Occurrence summary

Investigation number 200201846
Occurrence date 05/05/2002
Location 2.3 km ESE Bankstown, Aero.
State New South Wales
Report release date 04/05/2004
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Airborne collision
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer SOCATA-Groupe Aerospatiale
Model TB
Registration VH-JTV
Serial number 349
Sector Piston
Operation type Flying Training
Departure point Bankstown, NSW
Destination Bankstown, NSW
Damage Substantial

Aircraft details

Manufacturer Piper Aircraft Corp
Model PA-28
Registration VH-IBK
Serial number 28-7816511
Sector Piston
Operation type Private
Departure point Wagga Wagga, NSW
Destination Bankstown, NSW
Damage Destroyed

Boeing 737-376, VH-TAF

Analysis

As the 737 descended towards FL220, the crew was faced with the apparently conflicting demands of an ATC clearance and a TCAS resolution advisory. Given that the 737 was above the Brasilia, it would be normal for the initial TCAS advisory to have been a `reduce descent' or a climb advisory. Although no evidence of a TCAS or transponder malfunction was found, the investigation could not exclude the possibility of an equipment failure contributing to this incident.

It is possible that the crew may have misidentified the TCAS aural warning. Prompt action was required to resolve the apparent ambiguity, and the crew may have been guided more by the aural warning than by the IVSI display. That may have been, at least in part, due to the limitations of the IVSI display, where a pilot may initially rely more on the aural alert. Compared with a TCAS IVSI display, traffic information that is displayed on an EFIS screen increases the crew's situational awareness. However, pilots are trained to use all the information at their disposal and an aural alert would be the trigger to look at the IVSI display immediately. Therefore, if the green band of the IVSI was indicating a required rate of descent of 1200-1500 ft/min, then the correct procedure would be to disengage the autopilot and smoothly adjust the pitch to attain that rate of descent.

The probability that the crew of the 737 would receive a TCAS RA on the Brasilia could have been reduced had the Brisbane sector controller provided some indication to the crew of the 737 that there was another aircraft restricting further descent. That would have enabled the crew of the 737 to adjust their rate of descent in lieu of possibly maintaining a level and would have provided additional information that the crew could have then used to improve their situational awareness and optimise their decision making.

Summary

An infringement of separation standards occurred 70 NM east of Darwin, NT, between a descending Boeing 737-376 (737) and an Embraer EMB-120 (Brasilia) that was maintaining level flight. The event took place during the hours of darkness and in visual meteorological conditions. The crew of the 737 intentionally flew the aircraft through its assigned level in response to a traffic alert and collision avoidance system (TCAS) warning. The Brisbane sector controller also received a short-term conflict alert (STCA) between the two aircraft from the Australian Advanced Air Traffic System (TAAATS). The STCA alerted controllers when the radar trajectories of two aircraft indicated that separation standards might be infringed. The 737 and the Brasilia passed within 1.6 NM horizontally and 600 ft vertically. The required separation standard was either 3 NM or at least 1,000 ft.

TCAS is an airborne device that functions independently from the ground based air traffic control system and provides collision avoidance protection for a broad range of aircraft. The system fitted to the 737, TCAS II version 6.04, provided recommended escape manoeuvres in the vertical dimension, to either increase or maintain the existing vertical separation between the aircraft. The escape solution was communicated directly to the flight crew via a cockpit display and a synthesised voice attention getter. The TCAS alerts in the 737 used a liquid crystal display (LCD) instantaneous vertical speed indicator (IVSI) with red and green markings to indicate the vertical speeds to be avoided (red), and the desired vertical speed to be flown (green). The display was 70 mm square and had a fixed range of 6.5 NM. Aircraft were depicted using geometric symbols, depending on their threat status. A partial aircraft symbol was displayed at the extremity of the screen for aircraft detected beyond the display range. TCAS information could, in principle, have been incorporated in the electronic flight instrument system display (EFIS) of that aircraft but wiring and space available in the electronics racks of the aircraft would have required a major modification programme. TCAS information that is incorporated in the EFIS display allows the pilot to show traffic at longer ranges.

TCAS equipment interrogates the transponders of other aircraft to determine their range, bearing and altitude. Accordingly, the TCAS does not provide protection against aircraft that do not have an operating transponder. The Brasilia was fitted with an operating mode C transponder (altitude encoding) but was not TCAS equipped and the crew was not immediately aware of the infringement of separation standards. The Brasilia, which had 30 passenger seats and had a maximum take-off weight of 11,990 kg, was not required to be TCAS equipped by the Australian legislation current at the time. That legislation mandated the carriage of TCAS for all turbine-powered aircraft with more than 30 passenger seats or a maximum take-off weight greater than 15,000 kg. When both potentially conflicting aircraft are fitted with TCAS, both TCAS units co-ordinate their intentions to provide appropriate co-coordinated avoidance manoeuvres.

TCAS II can issue two types of alerts:

  • Traffic Advisory (TA) to assist the pilot in the visual search for the intruder aircraft and to prepare the pilot for a potential RA; and
  • Resolution Advisory (RA) to recommend manoeuvres that will either increase or maintain the existing vertical separation from an intruder aircraft.

Once the risk is over, the TCAS issues a synthesised voice `clear of conflict' message.

The 737 crew were on their fourth consecutive day of duty and completing the last sector of a four-sector day when the incident occurred. It took place at the transfer of control point between Brisbane Centre and Darwin Approach. The 737 was en-route from Cairns to Darwin and was on descent to FL220. The Brasilia was enroute to Groote Island, under the control of Brisbane Centre, with instructions to maintain flight level (FL) 210. Those routes placed the two aircraft on almost reciprocal tracks. As the 737 was passing FL235, the crew were instructed by the Brisbane sector controller to contact Darwin approach control for further descent, but were not advised of the opposite direction traffic.

The Manual of Air Traffic Services (MATS) gave guidance to controllers on how best to manage the situation and advised:

`6.6.5.5 Frequency change management in relation to the transit of an aircraft across airspace boundaries shall be arranged in a manner that normally enables pilot communication with the unit responsible for the airspace within which the aircraft is operating. A lateral tolerance of 10 NM either side of the boundary is permitted, except that when entering controlled airspace, the frequency change shall be within the 10 NM prior to the boundary.

6.6.5.10 Aircraft should normally remain on the frequency appropriate to the airspace in which it is operating. However, aircraft may be transferred to another ATS frequency provided that:

  1. significant operational advantage will be gained;
  2. workload, communications and equipment capabilities will permit the responsible controller to take such action as is necessary to preserve the separation without delay;
  3. the actual separation is in excess of the minimum;
  4. there is no possibility of separation being reduced to the minimum with the normal operation of the aircraft.'

MATS does not require controllers to provide traffic information to either crew in these circumstances.

In order to comply with MATS 6.6.5.10, the Brisbane sector controller could have either:

  • Initially assigned the crew of the 737, FL230 on descent, instead of FL220, then assigned the responsibility for separation to the Darwin approach controller, coordinating the terms of the transfer of the 737 with him, before transferring the aircraft to the Darwin approach frequency; or
  • Assumed the separation responsibility, coordinated the terms of the transfer of the 737 with the Darwin approach controller, and transferred the aircraft once the 737 had passed the Brasilia and a horizontal separation standard existed.

Airservices Australia believed that MATS section 6.6.5.10 did not apply to a change of frequency in these circumstances. According to Airservices Australia the action of the Brisbane sector controller, in assigning the crew of the 737 FL220, was consistent with MATS in that the controller applied a 1,000 ft separation standard between the two aircraft and the 737 crew was transferred to the Darwin approach controller within 10 NM of the lateral boundary between the Brisbane sector and Darwin airspace.

Shortly after acknowledging the instruction to change frequency, the 737 crew received an aural `traffic, traffic' warning and a display indication of an aircraft 5 NM ahead. The pilot in command stated that the TA quickly changed to a RA with a `descend, descend, descend' aural alert. As the aircraft was approaching its assigned level he disconnected the autopilot and pitched the aircraft nose down with the intention of following the RA commands. He stated that the required rate of descent shown on the IVSI was 1,200-1,500 ft/min. On passing FL220 the TCAS command abruptly reversed to a climb RA (aural `climb, climb now') which was followed positively. The climb annunciation continued until the aircraft was at FL225. No more commands were issued and there was no TCAS `clear of conflict', which is normally generated once a RA is removed.

Analysis of recorded data indicated that as the 737 descended through FL230, its rate of descent was approximately 2,900 ft/min. At FL227, the automatic flight system commenced a transition manoeuvre to achieve level flight at FL220. At approximately FL225 the autopilot was disengaged and the descent was continued manually at a rate of descent in excess of 3,200 ft/min to FL215. That was followed by a climb to FL225 at 2,900 ft/min as the pilot responded to the RA reversal (`climb now' advisory).

Maintenance files from the TCAS computer were examined and no indication of TCAS failure was found. Technical expertise was requested from the manufacturer of the TCAS equipment. Their evaluation of the event presented two possible scenarios.

`Explanation 1. The reported `descend' advisory was actually a `reduce descent' advisory that was misunderstood by the crew. A `reduce descent' would be consistent with the expected TCAS response per the reported geometry of the aircraft. Because the advisory was misinterpreted, the rate of descent was increased rather than decreased until the aircraft was below the TCAS required 700 feet vertical separation. Thus, the TCAS was required to issue a `climb now' advisory. The lack of a `clear of conflict' annunciation is explained in the following paragraph.

`Explanation 2. There is a possibility that the intruder aircraft's (equipped with mode C transponder) altitude report was not correctly received by the TCAS. There have been instances when a Mode C reply will not contain all the appropriate pulses in the message or it transmits pulses that are too narrow for the TCAS to detect. This could cause differing altitude reports and could result in multiple unstable tracks at different altitudes for the same intruder aircraft. This being the case, the TCAS could have issued a `descend' advisory for the intruder because it appeared (due to erroneous altitude report) that it was actually above its own aircraft. If subsequent replies had the correct altitude, the erroneous track would be dropped by the TCAS and the TCAS would issue a `climb now' advisory on the track with the correct altitude.

`The reason that `clear of conflict' was not annunciated can be attributed to low track firmness of the intruder aircraft. Mode C equipped aircraft are typically only equipped with a single antenna mounted on the lower hull. Since the intruder aircraft was below the 737 aircraft, it is likely that the TCAS was not able to receive regular replies at close proximity. The TCAS computer unit will `coast' the track of a previously established intruder file if it does not receive a valid or reasonable interrogation response. If the track of the intruder that generated the RA is coasted during the time of the associated RA, then the `clear of conflict' is not announced.'

Since the incident, the operator's TCAS software has been updated to Version 7. The objectives of the Version 7 update were to further increase the safety benefits of TCAS, make TCAS more compatible with the procedures used by ATC and to address operational concerns identified by pilots operating the older versions of TCAS. Improvements to the aural annunciations included a change from `reduce descent, reduce descent' to `adjust vertical speed, adjust'.

Occurrence summary

Investigation number 200201725
Occurrence date 24/04/2002
Location 130 km ESE Darwin, (VOR)
State Northern Territory
Report release date 25/11/2003
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 737
Registration VH-TAF
Serial number 23477
Sector Jet
Operation type Air Transport High Capacity
Departure point Cairns, QLD
Destination Darwin, NT
Damage Nil

Aircraft details

Manufacturer Embraer-Empresa Brasileira De Aeronautica
Model EMB-120
Registration VH-ASN
Serial number 120-056
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Darwin, NT
Destination Groote Island, NT
Damage Nil

Robinson R22 Alpha, VH-UXU

Significant Factors

The pilot was probably not aware of the existence of the powerline hazard.

The helicopter departed from the pad outside the operator's hanger at Mt Isa aerodrome at 1048 EST. The helicopter tracked west through the low ridge before detouring south, then turning north to the stockyards where the pilot landed to board the property manager. It remained on the ground for approximately 3 minutes before departing north east to conduct a search on a north west heading along the North Branch of Spear Creek. From there the helicopter turned left and tracked south east to a position east of the ridge. The helicopter then tracked south for approximately 3 km. It then turned right, onto a reciprocal heading, and tracked north to Spear Creek. It followed the creek north west for a short distance before turning further left to track south west back to the stock yards. The helicopter then manoeuvred around the sockyards before turning and tracking south along the western edge of the low ridges. The helicopter collided with the powerline, 5.5 km southwest of the aerodrome, at 1113.

Analysis

It is possible that the pilot may have intended to initially conduct an inspection flight to locate the missing cattle, however, after locating the cattle the nature of the flight changed to a mustering role and safety precautions normally carried out prior to mustering operations were not taken.

Visual cues, such as power poles, assist in the detection of wires. In this instance, the poles would have been partially obscured to the pilot's view by terrain and trees. Additionally, the angle subtended by the widely spaced poles would have placed them more towards the pilot's peripheral vision where they would have been less likely to be noticed.

The only visual cue to the pilot would have been the single-wire conductor. Even in bright sunlight conditions, a conductor dulled by oxidation would not have been readily discerned. In order for the pilot to have seen and avoided the powerline, he needed to be at the correct focal distance and looking directly at the wire.

Pilots operating at a low height should not rely on being able to see a powerline in time to take avoiding action.

Summary

The pilot and passenger of a Robinson R22 helicopter were conducting an aerial inspection and cattle mustering flight. During the flight, cattle were observed outside the fenced area and the pilot descended the helicopter to direct the cattle back towards the fence. The passenger then directed the pilot to fly the helicopter along the eastern fence to check its security. The passenger reported that the pilot had just commenced to climb higher, at his request, when the helicopter collided with a single-wire powerline. Recorded Global Positioning System data indicated that the helicopter struck the powerline at a speed of 55 kts. The wire did not break and the helicopter pitched nose down. The main rotor severed the tail boom and the helicopter collided with the ground 69 m beyond the powerline. It impacted in an inverted attitude, facing back along its direction of travel and rolled forward onto its left side. There was no evidence of fire in-flight or after the impact.

The main rotor, mast and upper right side of the helicopter cabin took the main impact and the mast was partially driven into the cabin. The pilot, who occupied the right seat, received fatal injuries. The passenger, although seriously injured, walked 200 m to a track and waited almost 2 hours until found by a passing motorist. The passenger reported that injury prevented him from picking up and activating the portable Emergency Locator Transmitter that was ejected from the helicopter cabin.

The powerline supplied electrical power to a nearby property and was aligned approximately east-west at right angles to the helicopter's flight path. It spanned a distance in excess of 500m from a pole in a saddle on a ridge east of the fence, to another pole set among trees in a timbered paddock. Strike marks on the wire indicated that the helicopter had struck the powerline at approximately mid-span. There were no markers on the powerline. Australian Standards (AS 3891.1-1991) specified markers on powerlines where the height of a cable exceeded 90m. The powerline did not exceed that height and at the point of contact was about 20m above ground level (AGL).

The pilot held a current Commercial Pilot Licence (Helicopter) and was appropriately qualified for cattle mustering operations. He held a valid Class 1 medical certificate and did not require any vision correction. An article on the visual aspects of wire detection by Dr Gordon Cable in the Directorate of Flying Safety-Australian Defence Force's special wirestrike edition (1997) of their safety journal "Spotlight" stated that under ideal conditions, the human eye can resolve detail down to an angle of 30 seconds of arc. That equated to being able to see a 5 mm thick wire from a distance of 150 m. However, contrast between the wire and the background against which it is viewed and the medium through which it is viewed, affect detection. The pilot was wearing a helmet with tinted visor. The fragments of perspex from the helicopter's windshield did not show any sign of being scratched or crazed.

The operator's Operations Manual required pilots to familiarise themselves with the area to be mustered, including any obstructions, before commencing mustering operations. Although the passenger had engaged the operator on previous occasions for the same work, no map of the area to be mustered was held on the operator's file. The passenger was aware of the existence of the powerline and stated that on previous occasions some pilots had him draw a "mud map" on the ground to indicate the area to be mustered, including powerline hazards. The pilot had reportedly not asked the passenger about any powerline hazards prior to the flight. There was no evidence that the pilot had previously flown over or inspected the area to determine the presence of hazards.

Occurrence summary

Investigation number 200201723
Occurrence date 25/04/2002
Location 5.5 km SW Mount Isa, Aero.
State Queensland
Report release date 15/11/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Wirestrike
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Robinson Helicopter Co
Model R22 Alpha
Registration VH-UXU
Serial number 0497
Sector Helicopter
Operation type Aerial Work
Departure point Hazlington Station, QLD
Destination Hazlington Station, QLD
Damage Destroyed

Boeing 747-338, VH-EBT

Safety Action

Local safety action

As a result of this incident, the operator reported that it has reviewed the door rigging procedures and determined that, `if a door-rigging defect has occurred then a full door rigging procedure should be carried out in accordance with the maintenance manual and scheduled in a `Heavy Maintenance' environment'.

Summary

Forty minutes after departing Cairns en-route to Japan, the flight crew of the Boeing 747-300 aircraft noticed the number 5 left main entry door warning light illuminate. The flight engineer investigated and found that the door handle had moved from its fully locked 4 o'clock position to an unlocked 3-o'clock position. The flight engineer, with the assistance of one of the cabin crew, attempted to move the handle back to the fully locked position but was unable to do so. Returning to the flight deck, a check of the aircraft's technical logbook revealed that this problem had occurred on previous occasions. The pilot in command contacted the operator's maintenance headquarters, where he was advised that the door would not be able to open due to the cabin being pressurised and the flight could continue on to destination.

The cabin crew were advised to monitor the door for the rest of the flight. Shortly before landing, the flight attendant seated adjacent to the door observed the handle moving slowly upwards. Just prior to touch down, the door handle jumped to the 2-o'clock position at which time a loud wind noise could be heard. Leaving his seat, the flight attendant grabbed the handle and forced it down. Paper was observed being sucked under the door as the passenger seated directly in front of the door (adjacent to the window) turned and grabbed the door handle giving assistance in pushing the handle down towards the locked position. The handle reached the horizontal 3-o'clock position with the flight attendant keeping weight on it until the aircraft had landed and taxied to the terminal.

A minor adjustment of the door upper gate was carried out by maintenance engineers before the aircraft's next departure. The next two flights were uneventful, however on the third flight the left main entry door-5 warning light again illuminated and the handle moved from the fully locked to the unlocked, 3-o'clock position. On arrival at the destination, an inspection by engineers found the force required to move the door handle from the locked to unlocked position was lower than required, necessitating further adjustments to the door. An entry was also made in the aircraft's technical log for a full rigging check and an inspection of the door bearings to be carried out on the aircraft's return to its main base. The aircraft then flew for two further flights, without any reported defects, before returning to its main base.

Upon returning to the operator's main base, the door was removed and disassembled for an inspection of the door bearings. No defects were found and the door was returned to the aircraft where it was refitted and a rigging check carried out. The aircraft was then returned to service.

Occurrence summary

Investigation number 200201617
Occurrence date 02/04/2002
Location 741 km N Cairns, Aero.
State Queensland
Report release date 21/10/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-EBT
Serial number 23222
Sector Jet
Operation type Air Transport High Capacity
Departure point Cairns, QLD
Destination Nagoya, Japan
Damage Nil

Boeing 747-338, VH-EBU

Safety Action

Local Safety Action

BoM advised that a fog forecasting team was formed in March 2002 to review the fog forecasting process at Perth. The team developed and implemented a systematic structured approach to forecasting fog in May 2002. The approach takes into account synoptic pattern matching, statistical data, model input and the impact of the Perth topography on fog formation.

Summary

The Boeing 747 aircraft was being operated on a scheduled passenger flight from Melbourne to Perth with an estimated time of arrival (ETA) at Perth of 0945 WST. The flight crew had been provided with an aerodrome forecast (TAF) for Perth, valid until 0600 the following day, which indicated that the visibility and cloud base would be above the alternate criteria throughout the period of the forecast. As there were no operational requirements, the aircraft departed Melbourne without alternate or holding fuel being carried for Perth.

Three minutes after the aircraft's departure from Melbourne, an amended TAF for Perth was issued with fog being forecast until 0800. After that time, conditions at Perth were forecast to improve above the alternate criteria. A trend type forecast (TTF) for Perth, also issued soon after the aircraft's departure, indicated that the visibility would be reduced in fog until 0800. Subsequent Perth TTFs issued from 0635 until 0759 indicated that the visibility would be reduced in fog or mist until 0800 when the conditions were forecast to improve above the alternate criteria.

The FLAKE waypoint, 465 NM east of Perth, was the flight planned point of safe diversion (PSD) based on a return to Adelaide. The crew obtained the 0730 Perth TTF that indicated an improvement in conditions above the alternate criteria from 0800 and, as the aircraft proceeded to the FLAKE waypoint, the Perth TTFs continued to forecast that improvement. The aircraft passed the FLAKE position at 0824 and soon after, a Perth TTF was issued that indicated the meteorological conditions would be below the alternate criteria until 15 minutes after the ETA of the aircraft at Perth.

As the aircraft was not fitted with an aircraft communications addressing and reporting system (ACARS), the operator's flight dispatch section attempted to contact the crew via high frequency (HF) radio but the attempts were unsuccessful. At 0845, a message from the operator about the 0825 TTF was provided to the crew by air traffic services. As the aircraft had flown past the PSD and fuel was not carried to divert to an alternate airport, the crew decided to continue the flight to Perth. The aircraft made an uneventful landing at 0938.

A report from the Bureau of Meteorology (BoM) indicated that a weak cold front with a fragmented cloud band was expected to move through the Perth area between 0800 and 0830. No showers were expected ahead of the front and the BoM aviation forecasters assessed the formation of fog in the expected weather situation as being unlikely. However, a weak ridge formed overnight ahead of the front and in the light wind regime caused by the weak ridge, advection fog formed at Perth Airport.

As the front approached Perth it became apparent to the aviation forecasters that the frontal passage was being enhanced by north-easterly winds in the Perth area. This meteorological situation resulted in reduced visibility and low cloud being observed until 0930. The forecasters had not previously encountered this type of situation, which produced a mix of advection fog and frontal fog that was difficult to forecast.

Occurrence summary

Investigation number 200201556
Occurrence date 22/03/2002
Location FLAKE
State South Australia
Report release date 18/06/2003
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Fuel - Other
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-EBU
Serial number 23223
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, Vic.
Destination Perth, WA
Damage Nil

Cessna 210N, VH-RRI

Summary

The pilot, the sole occupant of the Cessna 210 aircraft, was conducting a charter positioning flight from Groote Eylandt to Numbulwar. Witnesses reported that shortly after the aircraft took off from runway 10, it diverged to the right of the runway heading. The aircraft was reported to maintain level flight, at about 20 ft above ground level, and track towards the operator's ticketing office where a company pilot occupied the office, with the door closed, at the time. As the aircraft passed over the office it banked left and adopted a nose-high attitude. The witnesses then saw the aircraft hit a palm tree next to the office, and one saw an object fall from the aircraft. They then saw the aircraft lose altitude and disappear behind buildings. Shortly afterwards, the aircraft was observed on the ground, sliding towards the runway where it came to rest and an intense fire broke out. Although the pilot was able to exit the aircraft unaided, he later died from injuries sustained during the accident. The aircraft was destroyed by impact forces and post-impact fire.

The ticketing office was a converted shipping container situated next to a steel and corrugated iron shelter used as a passenger waiting area. There was a 6.6 m high very high frequency (VHF) aerial attached to the north side of the shelter and two large palm trees immediately south of the office. The office was approximately 150 m south of the runway centreline, 1130 m from the threshold of runway 10 and adjacent to the south-east corner of the sealed aircraft parking area. There was a light pole 5.2 m northeast of the VHF aerial.

The investigation established that the aircraft's left wingtip struck one of the floodlights on the light pole 5.2 m above the ground, detaching the floodlight, the wingtip and the aircraft's strobe light power unit attached to the outer wing rib. The left horizontal stabiliser struck the VHF aerial 5.6 m above the ground. The outer third of the left horizontal stabiliser and the left elevator were detached from the aircraft. A number of palm fronds were also detached from the two palm trees. The relative position of the impact marks indicated that the aircraft was in a left bank and nose-up pitch attitude at the time it struck the floodlight and aerial.

The damaged extremities of the left wing contacted the ground approximately 155 m from the light tower, leaving a shallow ground scar for 21 m before the propeller struck the ground. The aircraft continued to travel across the ground for a further 80 m before coming to rest, upright, within the runway flight strip immediately adjacent to the sealed runway surface. The landing gear and flaps were retracted and all flight control cables were intact and attached. The left wing and cockpit area were destroyed by fire. Ground contact marks and damage to the propeller were consistent with the engine delivering substantial power at impact.

The aircraft had been out of service for 2 months prior to the accident, due to difficulty in obtaining parts to complete a periodic maintenance inspection. The maintenance organisation completed the inspection on 22 March 2002. Although the current maintenance release had been damaged by the fire, there was no indication on the recovered parts of the maintenance release that any defects had been recorded on it. The accident pilot had flown the aircraft from Darwin to Groote Eylandt, via Gove, on the morning of the day before the accident. Another company pilot flew the aircraft on the afternoon of the day before the accident and again on the morning of the accident. The aircraft had completed 5.1 hours time in service since the periodic inspection and neither pilot had reported any aircraft defect that may have contributed to the accident.

The operator had three bases, with the chief pilot and check and training pilot both located at the head office in Darwin. Pilots new to the company were initially based at Groote Eylandt. At the time of the accident, there were three pilots and a base manager on the island. One pilot normally based on Groote Eylandt held the position of senior base pilot and had oversight of operational issues. On the morning of the accident, the senior base pilot had travelled from Groote Eylandt to Darwin. The base manager had oversight of administrative and maintenance issues on the island. The pilot had started flying for the operator on 4 January 2002 and after conducting 2 flights from Darwin, began operating from Groote Eylandt on 8 January 2002.

A check of the pilot's personnel files from his present and previous employers did not reveal any record of him being formally counselled regarding any aspect of his flying. Company personnel described the pilot as reliable and professional in all areas of his duties. Company personnel on the island reported that the pilot apparently slept normally on the night prior to the accident flight and did not exhibit any uncharacteristic behaviour on the day of the accident. Post-mortem and toxicological examination did not identify any factor which may have impaired the pilot's ability to operate the aircraft safely.

At the time of the accident, the automatic weather station at the airport recorded the wind as 9 kts, gusting to 15 kts, from 100 degrees magnetic. Witnesses reported that the weather was generally fine with scattered cloud.

The investigation was unable to establish why the aircraft diverged from the runway heading immediately after take-off.

Occurrence summary

Investigation number 200201100
Occurrence date 24/03/2002
Location Groote Eylandt, Aero.
State Northern Territory
Report release date 24/09/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Collision with terrain
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Cessna Aircraft Company
Model 210
Registration VH-RRI
Serial number 21064628
Sector Piston
Operation type Charter
Departure point Groote Eylandt, NT
Destination Numbulwar, NT
Damage Destroyed

Saab SF-340A, VH-KEQ

Safety Action

The ATSB recently released reports of the investigations into two occurrences that involved flight by high-capacity air transport aircraft into severe convective weather. For further information readers are directed to ATSB occurrence investigations 200100213 and 200105157 and associated safety recommendations. One of the safety enhancement aspects addressed by these recommendations included initial and recurrent training in the use and interpretation of airborne weather radar.

Significant Factors

CONCLUSION

  1. Due to the limitations of the airborne weather radar and possibly the radar antenna setting, the flight crew misinterpreted the depicted weather radar returns.
  2. The flight crew did not appear to understand the limitations of the airborne weather radar.
  3. The aircraft was inadvertently flown into an area of severe convective weather activity.

Analysis

The weather encountered by the crew was as forecast. Action taken by preceding aircraft confirmed the crew's expectation that they would have to divert to the left of track when en route. After leaving controlled airspace, the crew had to rely, for operational decision-making, on their interpretation of information derived from the airborne weather radar. That information supported their decision to divert and attempt to track around the southern end of the thunderstorm line.

When the aircraft was overhead Batemans Bay, the crew interpreted the weather radar returns as indicating that they could safely track direct to Canberra from that position. However, a severe thunderstorm was located on that track, as depicted by the 1823 Bureau of Meteorology radar image. The crew incorrectly interpreted the radar display of green and yellow returns as being acceptable. However, the heavy precipitation and hail produced by the storm cell was likely to have resulted in significant attenuation of the radar beam. Attenuation would have reduced the ability of the weather radar to accurately depict the precipitation intensity.

Further, the radar antenna setting of 3 to 4 degrees up, as reported by the crew, would have resulted in the radar beam scanning above the level at which the aircraft was flying, and into an area that was above the freezing level. It is likely that above that level the hail was dry. As such, it would have provided a low reflectivity target for the weather radar, and may have contributed to the inability of the radar to provide the crew with an accurate picture of the precipitation intensity.

The degree to which radar attenuation and reduced reflectivity, either individually or in combination, influenced the circumstances of the occurrence could not be determined. However, with inadequate radar derived information, the crew did not recognise the significance of the convective weather, and the aircraft entered the storm cell.

The warning generated by the GPWS computer was correct for the parameters within which it was operating. The excessive rate of descent derived by the radar altimeter and GPWS was the result of reflected returns from heavy rainfall and hail. When the crew received the GPWS warning their response was immediate and positive despite the aircraft being at an altitude well above the surrounding terrain.

Summary

On 26 March 2002, VH-KEQ, a Saab 340A aircraft, was being operated on a regular public transport flight from Sydney to Canberra. During the pre-flight planning, the crew identified a line of thunderstorms and associated weather moving through the weather forecast area (ARFOR) 21, in which the flight was to be conducted. Consequently, they anticipated that to avoid the adverse weather, they would probably have to divert to the left of the flight-planned track.

At the time, the weather in ARFOR 21 was under the influence of a low-pressure system that was situated over eastern New South Wales (NSW), with troughs aligned to the north and south. An upper-level disturbance was also present over central NSW. Because of this complex weather system, showers and thunderstorms were forecast over the eastern part of NSW during the afternoon and evening. A significant meteorological forecast (SIGMET) for thunderstorms was also current for ARFOR 21 at the time of the flight.

The forecast wind at 10,000 ft and 14,000 ft was 330 degrees true at 40 kts. The freezing level was forecast to be 11,500 ft to 12,000 ft.

The flight departed normally and, at 1750 ESuT, on first contact with Melbourne Centre, at approximately 50 nm to the southwest of Sydney, the air traffic controller advised the crew that there was significant weather on track between Marulan and Canberra. The controller told the crew that preceding aircraft diverted to the left of track to avoid this weather. The crew indicated that they also would divert left of track. The controller cleared the crew to divert to the left of track and once clear of the weather, to track direct to Canberra.

The crew of another aircraft that had diverted to the left of track reported to the controller that they had experienced moderate turbulence at flight level (FL) 140. The controller passed this information to the crew of KEQ, which at the time was climbing to FL120. At 1800, the controller advised the crew of KEQ that they would soon be leaving controlled airspace. Soon after, the crew reported that they would continue on their present heading as the weather radar indicated that conditions were unsuitable for tracking direct to Canberra. This heading resulted in the aircraft continuing to diverge from the flight-planned track. At 1805, they advised that they were descending from FL120 to 9,000 ft. The pilot in command later reported that this was to remain clear of the freezing level.

The pilot in command reported during a post occurrence interview that when the aircraft became clear of cloud they were over the coastline. Recorded radar information indicated that the aircraft was over the Batemans Bay area on the NSW south coast. After conducting a right orbit to confirm their position and to assess the weather, the crew decided to track direct to Canberra.

The pilot in command also reported that the crew was using the airborne weather radar in maximum gain mode, with the antenna tilt set at approximately 3 to 4 degrees up, and with the range at either the 25 or 50 NM setting. He reported that the radar displayed mostly green returns with an occasional yellow return. He also stated that there were no red returns on the radar. The crew interpreted information provided by the weather radar as being suitable to track direct to Canberra.

After setting course for Canberra, the conditions suddenly became dark, associated with an increase in the turbulence level and rain intensity. Shortly after, the ground proximity warning system (GPWS) sounded a `TERRAIN' warning. The crew applied maximum power and began to climb the aircraft, and at 1817, broadcast on the area frequency that they were climbing due to a GPWS warning. The pilot in command reported that during this event the outer pane of the front left windscreen shattered.

The crew continued the climb to FL110 and shortly after levelling the aircraft it became clear of cloud. They then climbed to FL120 and tracked direct to Canberra for an uneventful landing. Post flight inspection of the aircraft revealed that in addition to the shattered windscreen, the strobe lights had been damaged and several vortex generators were missing.

The pilot in command subsequently reported that he thought hail had been falling at the time the GPWS warning activated. Analysis of the recorded transmissions from the aircraft revealed background noise consistent with hail impacting the airframe.

The Bureau of Meteorology (BoM) `Letterbox weather radar' was situated about 27 NM south-south-west of Sydney, and about 90 NM to the north-east of Batemans Bay. The 1803 image from that weather radar was derived at a scan angle of 0.5 degrees. The returns from that area would, therefore, have been from an altitude of about 5,000 ft. Those returns revealed that a thunderstorm cell with reflected rainfall rates of over 100 mm per hour was located about 14 NM to the north-west of Batemans Bay. The 1823 image showed that the thunderstorm was almost overhead Batemans Bay, and on the direct track to Canberra.

BoM subsequently reported that the thunderstorm caused damaging winds and a tornado about 5 NM east of Braidwood, and that the storm was likely to have been a `supercell' thunderstorm.

Weather Radar

The aircraft was equipped with a WXR 200 colour weather radar. The radar antenna transmitted microwave energy in the form of pulses, which, if reflected off precipitation ahead of the aircraft, would be returned to the antenna. The radar beam was a narrow cone with a beam width of 8 degrees. The amount of energy reflected back to the antenna depended on the intensity of the precipitation, and was converted into a colour code for presentation to the crew on their flight instruments. There were four colour codes that were directly related to precipitation intensity, ranging from black (no precipitation), green (minimum detectable moisture), yellow (medium moisture level), to red (strong to extreme moisture level).

The Saab 340A operations manual described the operation of the airborne weather radar system. This information included the expected radar displays equating to reflected precipitation returns, and descriptions of how to avoid areas of severe weather based on weather radar displays. Information was provided on the reflectivity of various types of precipitation, with wet hail being the most reflective, and dry hail and dry snow being the least reflective.

The manual contained information in the use of the weather radar variable gain control. By reducing the gain, red areas of precipitation targets would eventually be displayed as yellow, and yellow areas as green. The red area that was the last to change to the next lowest level (yellow) would be the strongest part of the precipitation target.

The manual also contained information on weather radar antenna tilt setting, and the importance of precision tilt management for detection, analysing, and avoiding hazardous convective weather. The manual recommended that the antenna be set to the one degree down position whenever tilt and range were not being used for weather analysis. That setting provided pilots with a fast and certain means to ensure that the radar was functioning, and ensured the detection of weather returns ahead of the aircraft.

The manual also contained information that heavy rainfall could reduce the ability of the weather radar to provide a complete picture of the weather ahead. That phenomenon is termed `radar attenuation'. If a radar beam is fully attenuated, the display will indicate a radar shadow that appears to be the end of the precipitation area, but which actually extends further than is apparent from the display. Attenuation may reduce reflected precipitation readings by as much as 20dBz, which the weather radar interprets as an area of decreased rainfall. The effect of this is a downward colour shift that the colour returns displayed to the crew indicate a lower level of precipitation intensity than is actually occurring. What would normally be displayed as a red return (indicating strong to extreme rainfall rates, with the possibility of associated hail) is displayed as a yellow return.

Ground Proximity Warning System (GPWS)

The aircraft was equipped with a GPWS that provided 5 modes of protection. One of those modes provided protection against excessive closure rate to terrain. The GPWS processed radio height, flap and gear position logic, vertical speed and indicated airspeed to determine if a dangerous situation was developing with respect to the aircraft's height above the ground. The mode had two warning envelopes. Penetration of the first envelope resulted in a `TERRAIN' aural warning with the corresponding warning lights. If the second envelope was penetrated, the aural warning changed to a `WHOOP WHOOP - PULL UP' that was repeated until the aircraft gained 300 ft radio altitude.

Analysis of recorded flight data indicated that at the time the crew received the GPWS warning, the aircraft was at an altitude of 9,248 ft above mean sea level and flying at an indicated airspeed of 231 knots. The radar altimeter was indicating 2,154 ft and the derived rate of descent from the radar altimeter was 17,760 ft per minute. These parameters were within the warning envelope for the GPWS computer and resulted in a `TERRAIN' warning being provided to the crew.

Occurrence summary

Investigation number 200201228
Occurrence date 26/03/2002
Location 83 km ESE Canberra, (VOR)
State New South Wales
Report release date 19/12/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Weather - Other
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Saab Aircraft Co.
Model 340
Registration VH-KEQ
Serial number 340A-011
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Sydney, NSW
Destination Canberra, ACT
Damage Minor

Total power loss, Boeing 747-436, G-BNLD, 159 km north-west of Parkes, New South Wales, on 1 March 2002

Safety Action

Local safety action

Fan blade failure

The failure of the RB211-524 first-stage low-pressure compressor blade was the first to have originated from a pre-existing incomplete bond defect in the lower aerofoil section. Previous failures of a similar nature had occurred from areas of disbonding in the lower root-block section. In response to the disbond failures, the engine manufacturer had introduced the requirement to periodically inspect the root-block using conventional ultrasonic techniques (Service Bulletin SB72-9660).

In response to its revision of the acceptable bond-line defect size limit, the engine manufacturer issued Alert Service Bulletin RB.211-72-AE001 on 12 March 2002, instructing the removal from service of 109 low-pressure compressor blades that were considered to be at risk of cracking from incompletely bonded areas. The service bulletin was afforded 'Recommended' status and instructed removal of all nominated blades by 15 April 2002. In May 2002, a revision of the service bulletin was issued to include 77 additional compressor blades in the removal program. These components were identified as being at risk during a more extensive review of inspection records. In December 2002, advice was received from the engine manufacturer to indicate that all of the affected blades nominated by the original service bulletin and its revision had been traced and confirmed as removed from service.

RB.211-535 turbofan engines as fitted to Boeing 757 and Tupolev TU204 aircraft contain low-pressure compressor blades of a design similar to the RB.211-524 blades. Because of this similarity, the engine manufacturer considered that the RB.211-535 blades might also be at risk of a similar failure. To address this risk, the manufacturer issued Alert Service Bulletin RB.211-72-AE006, instructing the priority removal of 54 blades by 31 August 2002 or 30 October 2002, dependent upon the blades' service life. A further 58 blades were nominated for removal by no later than 28 February 2003. The UK Civil Aviation Authority approved service bulletin RB.211-72-AE001 on 12 March 2002 and service bulletin RB.211-72-AE006 on 24 April 2002.

Cabin communications

In recognition of the communication difficulties experienced by members of the cabin crew immediately following the engine failure event, the aircraft operator has implemented the following changes to the cabin operations.

a) In cases of an aircraft operating with known interphone unserviceability, a suitable emergency communication plan is now discussed and agreed upon during the pre-departure cabin and flight crew briefing.

b) Both normal and abnormal cabin communication scenarios are now included in the Safety and Emergency Procedures (SEP) training provided to flight and cabin crew.

c) An article discussing aspects of communication under emergency conditions has been published in the operator's cabin crew newsletter.

Technical Analysis Report

Technical Analysis Report: Examination of a Failed Rolls-Royce RB211-524 Turbofan Engine Boeing Commercial Aircraft Group, 747-436, G-BNLD

FACTUAL INFORMATION

History of the flight

On the evening of March 1, 2002, Boeing 747-436 aircraft G-BNLD sustained the failure of the number 3 (right inboard) engine during a scheduled regular passenger transport flight from Sydney to Bangkok. The flight crew experienced vibrations and received an ENG 3 REVERSER engine indicating and crew alerting system (EICAS) message. The crew shut down the number 3 engine and completed checklist items before returning the aircraft to Sydney.

An initial engineering examination found that a fan blade from the number 3 engine had failed, and that debris had punctured the engine cowl, the right wing leading and trailing edge flaps and the fuselage, damaging a structural member above the wing root area. The inspection found fractured fasteners and other components beneath the fan cowls and damage to the structure associated with the thrust reverser assembly. Debris from the number 3 engine was also found embedded within the intake cowl of the adjacent number 4 engine.

Factual Information

History of the flight

At 1729 on 1 March 2002, the Boeing 747-436 aircraft departed Sydney, Australia on a regular passenger transport service to Bangkok, Thailand. Approximately one hour into the flight, while the aircraft was in cruise at flight level 330 (FL330), the crew experienced the sudden onset of heavy airframe vibration and received an ENG 3 REVERSER annunciation from the engine indicating and crew alerting system (EICAS). The crew initially reduced the number-3 engine power and carried out the 'Engine Reverser Unlocked' actions from the aircraft quick-reference handbook (QRH). The crew stated that the engine appeared to be functioning normally at that time. After further EICAS status and advisory messages however, the crew elected to carry out other QRH checklists, concluding with the shutdown of the number-3 engine. The captain made a PAN call to air traffic control and subsequently an advisory announcement to the passengers. To reduce airframe vibration after the engine was shut down, the first-officer, who was the handling pilot, descended the aircraft to FL180 and reduced airspeed. A third crew member who was resting at the time of the event went back into the cabin to examine the engines and found extensive damage to the number-3 engine nacelle and strut fairings. After that information was reported to the flight crew, a further QRH checklist Fire Engine, Severe Damage or Separation was actioned, although at no time was there any reported indication or sign of fire. A decision to return to Sydney was made and fuel was jettisoned to establish a landing weight within limits. In consideration of the damage to the engine and to minimise the risk should the engine or components separate, an over-water approach to runway 34L was requested. The aircraft landed safely at 1947.

Injuries to persons

InjuriesCrewPassengersOthersTotal
Fatal    
Serious    
Minor    
None18272Nil290

Damage to the aircraft

The damage sustained by the aircraft was mainly limited to the number 3 engine and nacelle assembly. However, areas of isolated damage produced by the impact of debris escaping from the engine were found within the number 3 engine pylon, the right wing, flap, horizontal stabiliser and control surfaces and the right side of the fuselage.

Damage to the airframe

During the course of the on-site investigation, the operator carried out an inspection of the aircraft in accordance with the Boeing 747-400 maintenance manual, section 05-51-06 (Dragged engine nacelle / Engine seizure / Engine and strut damage condition - Maintenance practices - Conditional inspection). Australian Transport Safety Bureau Technical Analysis report number 20/02 section 1.6 summarised the results of that inspection. The most substantial airframe damage was identified as single punctures in the right wing centre leading edge flap section and the right side of the fuselage, between the cabin window and the upper wing surface. The actual point of debris impact was coincident with a bulkhead structure beneath the thinner fuselage skin. That combination of engine and airframe damage constituted an accident under Annex 13 to the Convention on International Civil Aviation.

Damage to the engines & nacelles

The ATSB carried out a general inspection of the failed engine before it was removed from the aircraft. The engine had sustained extensive damage to the low-pressure compressor, accessory equipment, thrust reverser assembly and the fan cowlings. A single fan blade had fractured from a location immediately above the dovetail rotor connection, releasing the full aerofoil length from the hub. Impact marks showed the blade to have struck the fan case at the one o'clock position (looking rearward), however the case was not compromised and the primary blade failure was contained within the engine. Subsequently however, the remaining fan blades had fragmented over the outer fifty percent of their length, with the liberated debris causing extensive tearing and multiple punctures of the intake cowl forward of the fan case. Two major fragment exit trajectories were identified during the inspection - those were aligned with the damaged areas on the fuselage and leading edge flap panel. The uppermost fragment exit trajectory passed through the forward strut region. Examination of that area revealed the separation of an engine to pylon connector that carried circuits for the monitoring of thrust-reverser position, turbine gas temperature and turbine speed and vibration.

Extensive mechanical damage associated with rotor imbalance loads was found amongst the engine accessory equipment and the thrust-reverser structure, which had separated from the front flange section at the riveted joint. That separation allowed the structure to move rearwards by up to thirty millimetres and transferred the retention loads for the thrust reverser unit and integrated nozzle assembly to the fan case hoop plate assembly. The engine manufacturer's stress modelling of the retention loads through that secondary load path showed that a significant reserve remained in the critical load path joint features, when considering the worst-case scenario of a three hour return extended twin-engine operations (ETOPS) flight [1].

Inspection of the adjacent (number-4) engine showed scratches, embedded fragments and other evidence of the ingestion of debris liberated from the number-3 engine. A boroscopic survey of the engine core intermediate and high-pressure compressor stages found blade distress that was typical of foreign-object damage.

Personnel information

The aircraft carried an operational flight crew of three and a cabin crew of fifteen. Additionally, a B757 pilot was a passenger. After the engine failure event, that pilot was requested to assist the flight crew in the management of the aircraft and the return to Sydney. Interviews following the event found that the crew were properly licensed and medically fit to conduct the flight.

[1] RB211-524 engines are also fitted to Boeing 767 twin-engine aircraft subject to ETOPS requirements.

Aircraft information

ManufacturerBoeing Commercial Aircraft Group
Model747-436
Serial number23911
RegistrationG-BNLD
Year of manufacture1989
Certificate of airworthiness (no.)033678/003 Issued 6 September 1999
Certificate of registration (no.)G-BNLD/R1 Issued 5 September 1989

Engine information

The Rolls-Royce RB211-524G engine (serial number 13340) had been installed on G-BNLD in November 1999 and had operated for 9,915 hours and through 1,299 cycles while fitted to that aircraft. The engine was originally manufactured in 1994 and had accrued a total life of 30,075 hours and 4,011 cycles at the time of the failure.

Fan blade information

The failed first-stage low-pressure compressor (fan) blade (part number UL29573, serial number GB77535) was manufactured in 1991. Since that time, the component had accumulated a service life of 32,000 hours and 9,444 cycles, with the last 8,915 hours and 1,299 cycles within engine 13340. The manufacturer's specified maximum service life for the blade type was 15,000 cycles.

Fan blade history and inspection

The manufacturer's service bulletin SB72-9660 specified three different periodic non-destructive tests aimed at detecting service-induced cracking, or damage in various critical parts of the RB211-524 blades. The manufacturer's records indicated that the failed fan blade had been overhauled on three separate occasions. The last overhaul was carried out in October 1999 and included the repair and polishing of the aerofoil surface and the replacement of the blade root dry film lubricant. Non-destructive inspections following the overhaul included a transient acoustic propagation (TAP) test, ultrasonic inspection of the root block and ultrasonic C-scan inspection of the blade aerofoil. Following the satisfactory completion of these tests, the blade was installed into engine serial number 13340 and the engine was fitted to G-BNLD. Of the non-destructive tests specified within SB72-9660, only the TAP test was applicable to on-wing inspections and was required at 200 cycle intervals. The TAP test was designed to detect the loss of vacuum within the internal cavity of the blade; indicating the presence of through-section cracking or other damage. Records from the engine manufacturer indicated compliance with the service bulletin, with the last TAP test carried out on 18 February 2002; ten days prior to the failure. Specific records documenting the results of that test were not available.

Cabin events

The cabin services director (CSD) reported the flight to have been normal until approximately one hour after takeoff. At the time of the engine failure the CSD was at the under-stair station talking with the First Officer on the flight deck via the cabin interphone system. The CSD reported hearing two loud thuds, followed by strong, continuing airframe vibration. Immediately looking out of a right side cabin door window, the CSD saw multiple holes in the number-3 engine cowling and pylon, through which he was able to see the ground below. He reported the weather as very clear and bright daylight. Returning to his station, the CSD attempted unsuccessfully on two occasions to contact the flight deck using the pilot alert interphone function, noting that some passengers were showing concern and wanting information. Instructing the cabin crew to stow the service equipment and secure the cabin, the CSD was about to attempt contacting the flight deck again when he was met by the third pilot who appraised the CSD of the situation. Further information was subsequently provided to the crew and passengers by the captain in a public address (PA) announcement.

A report from the rear cabin purser described the engine failure as a loud noise followed by juddering. Due to unserviceability with the cabin interphone system, the purser was unable to communicate with the CSD. The captain's PA announcement provided the first information to the rear cabin purser regarding the engine failure.

Cabin communication

Information gathered from the crew interviews and the aircraft technical log revealed that areas of the cabin interphone system were unserviceable at the commencement of the flight. To address this, the CSD had briefed the crew before flight for an alternative emergency communication procedure, requiring that pursers report to his station if an alert signal was given. Once he had assessed the event and the extent of aircraft damage, the third pilot assumed the cabin communications role and made several walk-around visits to the cabin to provide information and reassurance to the crew and passengers.

Flight deck security

In a response to a conference on enhanced aircraft security, the aircraft manufacturer had begun the implementation of a two-phase program to address perceived security deficiencies on board its aircraft. As part of its phase-one response, the aircraft operator had installed mechanical internal locks to the flight deck doors and implemented a policy regarding their use. The mechanical locks supplemented the pre-existing electric door locks and were only able to be operated by a flight crew member standing at the door. The electric door locks were capable of being operated by the flight crew in their normal, seated position. The operator's policy required the locking of the modified flight deck door before engine start and unlocking after engine shut down. The stated objective of the policy was to minimise the amount of time the flight deck door was unlocked and achieved this by providing specific procedures for crew interaction. These procedures relied extensively on the use of the interphone and alerting systems. While the minimum equipment list (MEL) documentation for the aircraft at the time of the event permitted operations with partial interphone unserviceability, it specified that the flight deck to cabin connection must be operational in order for the flight deck manual door lock to be used.

Shortly after the engine failure, the flight crew decided to abandon the locked door policy. That decision was taken to facilitate the use of the third crew member as a cabin to flight deck go-between role and to alleviate some of the problems associated with the interphone unserviceability.

Flight recorders

The aircraft was fitted with a Sundstrand Data Control Universal Flight Data Recorder (UFDR). Following the occurrence, the UFDR was removed from the aircraft and a copy of the recorded data was made by the ATSB. The aircraft was also fitted with a Quick Access Recorder (QAR) unit. The data from this device was downloaded by Qantas Airways Limited and the information applicable to the accident was forwarded to the ATSB[2]. The recovered data from both UFDR and QAR was used to prepare a summary of events and actions during the flight. A print out of the aircraft EICAS log obtained from the aircraft flight deck was used to supplement the recorder data.

The first indication of an anomalous engine condition was recorded at 07:24:15 UTC, with an interruption in the low-pressure spool (N1) speed data from the number-3 engine. One second later, the engine fuel flow and the exhaust gas temperature (EGT) for that engine began to decrease, accompanied by an 'in-transit' annunciation from the thrust reverser system. Another three seconds later (07:24:19), the data showed a reduction in throttle angle and a marked increase in the broadband vibration levels for the number-3 engine. The EICAS captured two 'auto' events at 07:24:22 and 07:24:26; both events showing a loss of N1 and N2 speed, loss of vibration data, a drop in EGT and a loss of fuel flow and oil pressure. The system also flagged multiple number-3 engine faults including the advisory messages ENG 3 FUEL V/V and the reported ENG 3 REVERSER. At 07:24:32, the number-3 engine generator circuit breaker opened and was accompanied several seconds later by a loss of voltage on the number-3 integrated drive generator bus. A loss of data for the engine thrust reverser position, exhaust gas temperature and compressor outlet temperature also occurred at this time. Eight seconds later, data was lost for the engine pressure ratio (EPR) and throttle position.

A comparison of the broadband and individual turbine spool vibration levels produced by the number 3 engine during the time leading up to the failure showed no indications of trends that might have suggested a developing problem.

Tests and research

The ATSB examined the root section of the released fan blade (s/n GB77535), assisted by authorised representatives from the engine manufacturer.

Failure of the blade occurred as a direct result of fatigue cracking propagating transversely through the lower aerofoil section. The origin of cracking was from the upper edge of a pre-existing internal defect at the bonding line between the two titanium alloy plates used to manufacture the blade. Fracture surface features indicated crack growth over multiple flight cycles, continuing to a point where the remaining section failed in ductile tensile overload, releasing the blade aerofoil from the hub. Analysis of the number and nature of the arrest marks extending from the point where the cracking first broke the external surface suggested that around forty flight cycles might have elapsed before final blade failure.

[2] Quick-access recorders are fitted to aircraft as a maintenance tool for the operator and as such, the ATSB does not routinely download data from these units.

The original manufacturing bond-line defect was roughly circular in form and measured approximately twelve millimetres in the chord-wise dimension. Planar growth of the defect by debonding had occurred to a chord width of around twenty-two millimetres. Examination of the blade manufacturing records showed that the original defect had been detected and quantified by radiographic inspection during blade fabrication. Due to the inherent difficulty in achieving flawless bonding within the blade root block area, criteria for the fitness-for-purpose assessment of blades with bonding discontinuities had been developed. The failed blade had been 'concessionally accepted' for service using these criteria.

Following the blade failure, the manufacturer carried out computational stress modelling of a range of incomplete bond defects and determined that the defect in blade GB77535 was located in one of the two most critical locations for generating high stresses and subsequent fatigue cracking. It was also determined that a defect six millimetres in diameter was the largest area of incomplete bond tolerable under the existing declared blade lives.

ATSB Technical Analysis section number 200200646 (20/02) details the examination of the failed blade and the associated engine damage.

Significant Factors

  1. During the 1991 manufacture of the first-stage low-pressure compressor blade serial number GB77535, a small area of incomplete bonding remained within the interface between the two titanium alloy plates used to fabricate the blade component.
  2. The presence of the incompletely bonded region was detected during preliminary non-destructive inspection, however the blade was accepted for service under the manufacturer's 'concessional assessment' program.
  3. The maximum acceptable bond-line defect size limits as specified by the concessional assessment program were too large to ensure that fatigue cracks could not initiate and propagate to failure within the prescribed life limit of the blade components.
  4. None of the manufacturer's prescribed periodic in-service inspections carried out on the blade during its life had detected the incomplete bond defect. None of these inspections were specifically designed for the detection of defects within the lower aerofoil section where the defect was located.
  5. Fatigue cracking initiated and propagated from the upper edge of the bond-line defect in response to service loading conditions.
  6. Fracture and release of the fan aerofoil section from the rotor occurred after growth of the cracking to critical size.
  7. The number-3 engine failed from damage sustained during the blade failure event.
  8. The aircraft sustained minor airframe and number-4 engine damage resulting from impacts with blade debris liberated from the number-3 engine nacelle and cowling.

Summary

Approximately one hour after departing Sydney on a regular passenger transport flight to Bangkok, Thailand, the Boeing 747-436 aircraft, registration G-BNLD, sustained the failure of the right inboard (number 3) engine, necessitating a return to Sydney airport where an uneventful one-engine inoperative landing was made.

Failure of the number-3 engine resulted from the fracture and liberation of a single first-stage low-pressure compressor (fan) blade. The blade failed through the lower aerofoil section, immediately adjacent to the dovetail connection with the rotor disk. While the initial blade impact was fully contained by the fan casing, many fragments of the fractured blade and the damaged adjacent blades punctured the intake cowling or escaped forward of the nacelle, producing damage to the wing, control surfaces, fuselage and the number-4 engine. Imbalance forces generated by the blade loss produced extensive damage to the engine accessory components and disrupted the primary load-bearing path between the engine fan case and the thrust reverser assembly.

ATSB laboratory examination of the retained root section of the failed blade established that fatigue cracking had initiated and propagated from a pre-existing defect at the blade centreline. The defect was characterised as a 'lack of bond' feature at the interface between the two sandwiched titanium alloy panels used to form the blade. Fatigue cracking had initiated from the upper edge of the defect and propagated under operationally induced bending and centrifugal loads.

The lack of bond defect had formed during manufacture of the blade in 1991. While it was detected during manufacturing inspections, the defect was assessed as non-critical and the blade was accepted for service under the engine manufacturers 'concessional acceptance' system. The blade subsequently accrued a service life of 9,444 cycles and 32,000 hours before failing; this representing 63% of the 15,000-cycle design prescribed blade life.

In response to the blade failure identified in the investigation, which was the first of its type, the engine manufacturer has revised the acceptable bond-line defect size limit and issued a series of alert service bulletins, requiring the removal from service of 186 RB.211-524 blades and 112 similar RB.211-535 blades. These were 'concessionally accepted' components that, on review of the manufacturing documentation, had been assessed as being at risk of failure from a similar mechanism. In December 2002, the engine manufacturer advised that all blades identified by the service bulletins had been traced and confirmed as removed from service.

Occurrence summary

Investigation number 200200646
Occurrence date 01/03/2002
Location 159 km NW Parkes, (VOR)
State New South Wales
Report release date 24/09/2003
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Accident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration G-BNLD
Serial number 23911
Sector Jet
Operation type Air Transport High Capacity
Departure point Sydney, NSW
Destination Bangkok, Thailand
Damage Substantial

Aerospatiale AS.350B2, VH-WFX

Analysis

No evidence was found to suggest that the helicopter was not serviceable prior to the occurrence. No mechanical issues could be established as contributing to the occurrence. The reason for the anomaly that led to the vertical vibration reported by the pilot could not be established. The excessive loading indicated by the starflex rotor arm fractures would not be expected to be encountered under normal service conditions but could occur during a ground resonance event. The damage to the helicopter components was consistent with damage previously documented as a result of a ground resonance event.

Summary

The AS350B2 Squirrel helicopter was being operated on a private flight with the pilot and two passengers on board. The pilot reported that shortly after lifting the helicopter into an approximately 1.2 metre hover, he noted that the main rotor system had a pronounced vertical, once per revolution, vibration. The pilot then elected to terminate the hover and land the helicopter. He further reported that when the skid landing gear touched the ground, the helicopter began to oscillate violently. The pilot then activated the emergency fuel cut-off. Subsequently, the engine and main rotor revolutions per minute (RPM) began decreasing. The pilot and passengers reported that the oscillations of the helicopter became more violent and pronounced as the main rotor RPM decreased. Once the main rotor ceased rotation, the occupants exited the helicopter. One passenger received minor injuries.

The helicopter sustained substantial damage to the main rotor assembly, the right landing gear skid, the forward cargo mirror mount bracket, the left and right structure keel beams, and the right rear passenger seat support. The principle damage to the main rotor assembly consisted of the fracture and separation of the yellow and blue starflex rotor arm outboard segments.

An examination of the helicopter main rotor head and blades did not reveal any anomalies, other than the separated starflex rotor arm outboard segments, that could have resulted in the vertical vibration reported by the pilot. A witness near the helicopter during its hover flight did not report any foreign objects or birds in the area of the main rotor disc during the flight.

The damage to the main rotor starflex rotor assembly was consistent with the damage documented in a technical report compiled by the Australian Defence Science and Technology Organisation relating to a previous military AS350 helicopter occurrence. That report indicated that the starflex rotor arms failed due to severe upward bending due to excessive loading. That investigation determined that the circumstances of the accident were consistent with a ground resonance event.

Occurrence summary

Investigation number 200200651
Occurrence date 01/03/2002
Location Williamtown, Aero.
State New South Wales
Report release date 08/08/2003
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Accident
Highest injury level Minor

Aircraft details

Manufacturer Aerospatiale Industries
Model AS350
Registration VH-WFX
Sector Helicopter
Operation type Private
Departure point Williamtown, NSW
Destination Brandy Hill, NSW
Damage Substantial

Cessna 500, VH-HVM

Summary

During planned stop-work meeting by air traffic controllers, Airservices Australia (Airservices) enacted a contingency plan for the Melbourne Flight Information Region (FIR). That plan amended Class A and C controlled airspace (CTA) to temporary restricted airspace (TRA) and limited the number of aircraft able to fly in the TRA. The plan required pilots of aircraft not approved to fly in the TRA to leave controlled airspace by 1015 CSuT. A Cessna Aircraft Company Citation (Citation) was seen on radar to be operating in the TRA after that time and in potential conflict with a Boeing Company 737 (737). The Adelaide Approach East controller issued traffic information and clearances to enter controlled airspace to the pilots of both aircraft that ensured their separation.

There were no separation standards applicable to aircraft in the TRA. Recorded radar data indicated that the vertical and lateral spacing between the aircraft exceeded the vertical separation standard of 1,000 ft (for aircraft below flight level (FL) 290) and the radar separation standard of 5 NM that would normally apply to aircraft in CTA.

Civil Air, the Australian Air Traffic Control Association notified Airservices of the proposed stop work meeting on 8 March 2002. On 12 March 2002, Airservices issued a notice to airmen (NOTAM) C22/02 regarding the controllers' standdown period between 1030 to 1430 on 13 March 2003. That NOTAM advised that a temporary restricted area and limited route structure would be activated and that specific details would be notified by a subsequent NOTAM. Later that afternoon, Melbourne FIR NOTAM C708/02 was issued advising that pilots of aircraft not in receipt of an approval to operate in the TRA were to be clear of CTA by 1015.

During the morning of 13 March 2002, sometime between 0830 and 0900, the Citation pilot telephoned Airservices requesting approval to fly in the TRA. That request was denied and the pilot subsequently planned to leave CTA, by descending en route, at 1015 in accordance with the NOTAM. The 737 pilot was approved to fly in the TRA.

Prior to the activation of the TRA, the two aircraft were under the control of the Melbourne Centre Canty sector controller. At about 0930, that controller received a temporary local instruction and other documents that detailed how the Canty airspace would be transitioned from CTA to TRA. An FIR Manager was available to assist controllers in the Barossa Group, of which Canty was one sector. At 1020, the Citation pilot requested a clearance to descend to FL200, a level outside the TRA. The Canty sector controller approved the descent but then advised the pilot that he could remain in the TRA. The pilot acknowledged that radio transmission and advised the controller that he would remain in the TRA. The controller was not aware of what aircraft were approved to operate in the TRA.

The plan called for controllers to record details of aircraft that remained in the TRA for subsequent checking by a manager. The intention was to confirm that only aircraft approved to fly in the TRA were actually in the area. At 1025, the controller broadcast that control services were terminated and those pilots should operate in accordance with the TRA NOTAM and closed the Canty sector control position. The controller recorded that both the Citation and the 737 were in the TRA. As Melbourne Centre staff were checking the approval status of the aircraft remaining in the TRA, they were notified by Adelaide Approach controllers that the Citation was in the area without approval.

The contingency plan was developed in 1997 to provide a structured response to, and recovery from, a failure of air traffic services. The plan was reviewed in 1998 - 1999 in preparation for the information technology problems expected during the 2000 new year, and updated in 2001. The plan was broad based and there was limited detail on how it may actually be implemented. When Airservices was notified of the controllers' standdown, it was perceived that a limited segregation service, using the plan, could be offered to assist the aviation industry. The plan was modified in conjunction with the two primary airline operators and the resultant contingency plan complemented their individual company plans.

More detailed local plans, to address the transition to/from the contingency plan, were developed during the period before the notified standdown. Those local plans were not developed in accordance with Airservices safety management processes.

A review of the plan and associated procedures was conducted following the standdown and considerable changes were made before a second similar standdown, involving Sydney and Brisbane controllers, a week later. A further review was conducted after the second standdown and, as a result of both reviews, 139 items were identified for action. A safety assessment of the contingency plan was subsequently conducted in April 2002 resulting in further changes to the plan. Those changes also included limiting the future declaration of a TRA to Class A and C airspace over Australian territory.

Occurrence summary

Investigation number 200201025
Occurrence date 13/03/2002
Location 130 km ENE Adelaide, (VOR)
Report release date 15/01/2004
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Airspace related - Other
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Cessna Aircraft Company
Model 500
Registration VH-HVM
Serial number 5000349
Sector Jet
Operation type Private
Departure point Bankstown, NSW
Destination Adelaide, SA
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 Brisbane, QLD
Destination Adelaide, SA
Damage Nil