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

Piper PA-31-350, VH-TTX

Summary

While climbing through 600ft after take-off, the left engine of a Piper Chieftain failed. The pilot then completed the engine failure drill, shut down the engine and feathered the propeller. He then returned the aircraft to Bathurst Island.

Initial company engineering examination found that the crankshaft in the left engine had failed. The engine was removed and forwarded to the ATSB for examination.

During disassembly of the engine, the crankshaft was found to have failed at the shoulder of the number three main bearing journal and also through the throw of the number four crank arm. When separating the crankcase halves, it was noted that the main crankcase through studs had lost the fastening torque on all of the securing nuts. That allowed the studs to move within the crankcase stud housings and the crankcase halves to move relative to each other. Fretting wear of the stud non-threaded sections was evident from the resultant movement of the crankcase halves. Examination of the technical records for the engine showed that it had undergone a top overhaul inspection 231.9 hours prior to the crankshaft failure.

The ATSB Technical Analysis team examined the broken crankshaft segments. The analysis determined that the crankshaft fracture was caused by fatigue crack growth through the number three main bearing journal and the number four connecting rod crankarm. Fatigue cracking initiated at the forward fillet of the number three main bearing journal and was associated with surface damage created by contact with the number three main bearing inserts during engine operation. It was evident that those main bearing inserts had moved forward in their housing during engine operation, but they had not rotated in the housing.

Secondary fatigue cracking had initiated at the forward fillet of the number three connecting rod journal and extended a short distance into the number three connecting rod and number three main crankarm. Final fracture in that crankarm occurred as a result of the presence of the small fatigue crack and abnormal loading following the fracture of the number three main and number four rod crankarm.

A summary of broader issues involving this engine failure and similar engine failure occurrences is in the ATSB's report 200002157.

Occurrence summary

Investigation number 200102544
Occurrence date 09/06/2001
Location 4 km SE Bathurst Island Aero.
State Northern Territory
Report release date 24/12/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Piper Aircraft Corp
Model PA-31
Registration VH-TTX
Serial number 31-8152034
Sector Piston
Operation type Air Transport Low Capacity
Departure point Bathurst Island, NT
Destination Darwin, NT
Damage Nil

Cessna T207A, VH-KAX

Safety Action

Local safety action

The operator reported that, to ensure integrity, they had conducted an inspection of all flight control rod ends for the company fleet of aircraft.

Summary

A Cessna T207A aircraft, with seven persons on board, was departing Jabiru for a local scenic flight. The operator reported that the control rod end for the right aileron disconnected and the aileron deflected upwards shortly after the aircraft had rotated for take-off. The take-off was continued as there was insufficient runway remaining to stop the aircraft. A significant amount of left aileron input was then required to counteract the tendency for the aircraft to roll right. The pilot was able to conduct a normal left circuit and landed the aircraft safely at the departure runway. There were no injuries to passengers or crew, and no damage to the aircraft.

The investigation found that the swivel joint for the rod end, which attached to the outboard end of the right aileron control rod, had fractured and separated at the base of the threaded section. The rod-end fitting consisted of a rounded but flat-sided cast-alloy housing with a threaded tail section, which was attached to the interconnecting drive rod from the wing. The housing contained a spherical bearing with a bolt through the centre (at ninety degrees to the threaded tail) which connected the drive rod to the aileron control surface.

Metallurgical examination confirmed that the rod-end bearing had seized in the housing due to surface corrosion on the sliding surfaces. That action had exposed the threaded shank section of the fitting to elevated bending loads, rather than the push-pull loads for which it was designed. Cracking then initiated and propagated, through about 50% of the rod-end cross section, under normal operating conditions over an extended period before finally separating.

Examination of the maintenance documentation for the aircraft showed that the failed rod end was fitted to the aircraft as a new item on 14 Oct 1999. The rod end failed in service on 13 June 2001. At that time, it had completed a total of 754.3 hours time-in-service. The rod ends did not have a time-in-service life and were listed by the manufacturer as an "on condition" item.

The company reported that it had a policy of changing all control rod swivel-end fittings when their aircraft underwent repainting; approximately every 4-5 years. The investigation was unable to determine why the rod end was not changed at the last repaint.

Occurrence summary

Investigation number 200102538
Occurrence date 10/06/2001
Location Jabiru, (ALA)
State Northern Territory
Report release date 14/03/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Flight control systems
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Cessna Aircraft Company
Model 207
Registration VH-KAX
Serial number 20700630
Sector Piston
Operation type Charter
Departure point Jabiru, NT
Destination Jabiru, NT
Damage Nil

Boeing 737-476, VH-TJR

Summary

Prior to the first flight of the day, the Boeing 737 aircraft cabin was found to contain smoke and fumes. While the crew returned to the crew room, maintenance personnel inspected the aircraft and found that the auxiliary power unit (APU) had malfunctioned. The cabin was cleared of fumes and the aircraft despatched with an unserviceable APU. For a short time after take-off, some smoke and fumes were observed in the cabin but cleared.

At around 6,000 ft on approach to Sydney, fumes were again detected; most noticeably in the rear of the cabin. A fast approach and normal landing ensued. Cabin staff reported that the smell dissipated when the air conditioning packs were selected to HIGH.

Company maintenance investigation found that the APU malfunction was the result of a cooling fan shaft failure. The failure allowed APU turbine oil to leak from around the shaft seal from where it was sucked into the APU inlet prior to the APU control unit initiating an auto-shutdown. The oil then entered the air conditioning system ducting and later exited into the cabin as fumes and oily smoke during that system's normal operation.

Occurrence summary

Investigation number 200102326
Occurrence date 29/05/2001
Location Cairns, Aero.
State Queensland
Report release date 06/02/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Air/pressurisation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 737
Registration VH-TJR
Serial number 24443
Sector Jet
Operation type Air Transport High Capacity
Departure point Cairns, QLD
Destination Syndey, NSW
Damage Nil

British Aerospace Plc BAe 146-100, VH-NJR

Safety Action

On 6 September 1999, the then Bureau of Air Safety Investigation 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 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 short taxi distance after landing limited the opportunity for the crew to investigate the origin of the contaminated air. However, only one air conditioning pack was in use and the APU was the sole source of air to that pack. The APU was found to be producing fumes during the day following the incident and it is considered that it was likely to have been producing fumes on the day of the incident.

By the time the aircraft was parked, the APU had almost certainly been passing oil fumes to the number 1 pack for about five minutes. Some of the crew felt increasingly unwell during the subsequent engine start even though no air supply source was selected. That may have been a result of residual fumes in the air conditioning ducting being circulated by the cabin fan.

There was no doubt that fumes contaminated the cabin and flight deck. The pilot in command became aware that the fumes had caused a detrimental effect to his performance and he took appropriate steps to terminate the flight. The implication that the fumes may have had a subtle but adverse affect on the pilot's decision-making process was not conclusively determined.

Summary

The BAe 146 aircraft had departed Brisbane, Qld on a flight to Mackay, Qld with a carried-forward defect that required the number 1 air conditioning pack to be used as the sole source of air for the cabin and flight deck. That situation was permissible under the terms of the aircraft's Minimum Equipment List (MEL), which allowed operation of the aircraft in non-standard configurations. The number 2 pack was not to be used because an intermittent oil leakage in the number 4 engine was a potential source of air contamination to air conditioning pack two.

During normal operation, bleed air from engines one and two was fed to pack one which in turn normally supplied conditioned air to the flight deck and cabin. Bleed air from engines three and four was fed to pack two, which normally supplied air to the cabin only. Additionally, bleed air from the auxiliary power unit (APU) was used by either pack during the take-off and landing phases or when air conditioning was required on the ground.

The flight to Mackay was uneventful. During the approach to land, the APU was selected as the bleed air source for pack one and the configuration remained that way until the aircraft was parked, the engines were shut down and the passengers disembarked.

From the time the aircraft turned off the runway, the crew was aware of a strong oil smell coming from the air-conditioning system. The fumes were detected in the cabin as well as the flight deck. Because it was a short taxi distance and a busy period on the flight deck, the crew did not have time to investigate the origin of the contaminated air. Although the smell was generally described as oil-like, the moderate south-east surface wind may have added to the air contamination by directing engine exhaust fumes into the APU air intake.

The pilot in command vacated the aircraft to get some fresh air and a short time later he suffered headache, itchy eyes, nausea and a bad taste. Company engineers at the Brisbane and Adelaide bases were consulted by telephone and a decision was made to proceed with the scheduled return flight to Brisbane using engine air one and two as the sole source of air to pack one. As the pilot in command was still suffering from the symptoms described above, he checked with the first officer and confirmed that he was unaffected by the fumes incident and requested the first officer to be the handling pilot on the next sector.

The passengers were embarked, the doors were closed and the engine start procedure was commenced. During the turnaround, the air conditioning had been turned off and remained off during the engine start. However, the cabin fan, which distributed air to the cabin through individual louvres above each passenger seat, was on. After starting three of the four engines the pilot in command felt increasingly unwell and the cabin staff also became aware that they were being affected by the fumes. The pilot in command then cancelled the flight and later expressed concern that he had considered attempting a flight while still feeling the effects of the air contamination. He stated that he may have been influenced by his desire to consult his Designated Aviation Medical Examiner in Brisbane as soon as possible. He also noticed that he had made simple errors during the flightdeck preparation and put those errors down to the effect of the fumes on his thought processes. Previous incidents have indicated that operating crews were not aware of their impairment and the subsequent effect on their decision making ability. The seriousness of that aspect was reflected in the decision by the Civil Aviation Safety Authority (CASA) to adopt a United Kingdom Air Accidents Investigation Branch (AAIB) recommendation requiring flight crew to use oxygen masks selected to 100 percent when there is a suspicion of flight deck or cabin air contamination.

A Licensed Aircraft Maintenance Engineer (LAME) was dispatched to Mackay to investigate the source of the fumes. The engineer carried out an inspection in accordance with a CASA airworthiness directive AD/BAe146/086, issued 30 March 2001, and British Aerospace Systems Information Service Bulletin (ISB) 21-150. The ISB 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. The engineer's inspection of the air conditioning system, engines and APU revealed no signs of oil contamination or oil leaks. The aircraft was ferried to Brisbane where further investigation, including an air test, confirmed that the number 4 engine was producing fumes during the climb and the descent and the APU was continuously producing fumes. Subsequently the number 4 engine and the APU were replaced.

The two cabin staff received medical advice and resumed their flying duties. Medical tests were carried out on the pilot in command but no abnormalities were detected and he resumed flying duties one week after the incident. The co-pilot was unaffected by the fumes.

Particular attention has been paid to this type of problem in Australia since July 1997 due to apparently similar incidents and crew reaction. A number of organisations, including the ATSB, have been conducting investigations into the subject of air quality in BAe146 aircraft. Evidence from previous incidents of air system contamination on this type of aircraft has indicated that the fumes are associated with engine or APU oil contamination of the air conditioning system. As a result, operators have incorporated various modifications to the cabin air system, APU and engines. They have also introduced improved maintenance practises to further address the issue. However, that action has not completely solved the problem. The air supplied to the air conditioning packs is protected from contamination by oil seals in the engines and APU. A technical defect arising in one of these seals can result in oil entering the cabin air conditioning system with the first signal of the defect being an awareness of fumes by the members of the crew. The difficulty of identifying the origin of the contamination is exacerbated by the often intermittent nature of the fume events.

Occurrence summary

Investigation number 200102467
Occurrence date 31/05/2001
Location Mackay, Aero.
State Queensland
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-NJR
Serial number E1152
Sector Jet
Operation type Air Transport High Capacity
Departure point Brisbane, QLD
Destination Mackay, QLD
Damage Nil