Boeing 737-376, VH-TAX

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

The crew of a departing Boeing 737 (B737) reported that as they were climbing to 5,000 ft on a standard instrument departure from runway 27 at Melbourne, they saw an arriving B737 on descent in their 12 o'clock position, passing from right to left. The departing aircraft's traffic alert and collision-avoidance system indicated that there might have been less than the required radar separation standard of 3 NM between the two aircraft. The crew was not alerted by air traffic control regarding the arriving B737.

Radar data and air traffic control automatic voice recordings were reviewed to establish the sequence of events. The investigation found that the Departures controller had assigned responsibility for separation to the pilot of the arriving B737, which was tracking for left downwind runway 34. The transmission from air traffic control to the crew of the descending B737 included the statement "...clear of the 737 out to your left, descend to 3000".

Airservices Australia advised that the procedure was used when separating runway 27 departing aircraft from arriving aircraft tracking on left downwind for runway 34. The aim was to release the climb and descent restrictions of both aircraft as soon, and as efficiently, as possible. The procedure of one aircraft sighting and confirmed past the other aircraft was considered to be a legitimate technique in such situations.

Visual separation of air traffic may have been a valid method to use in those circumstances. However, the criteria for its application 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 departing B737 was an IFR aircraft but was not provided with the required traffic information.

Occurrence summary

Investigation number 200101747
Occurrence date 18/04/2001
Location 5 km W Melbourne, (VOR)
State Victoria
Report release date 04/02/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category ANSP info/procedural error
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 737
Registration VH-TAX
Serial number 23489
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination Perth, WA
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 737
Registration VH-CZF
Serial number 23658
Sector Jet
Operation type Air Transport High Capacity
Departure point Unknown
Destination Melbourne, VIC
Damage Nil

Boeing 747-438, VH-OJJ

Safety Action

Local safety action

Rolls Royce Ltd

Following the occurrence, the engine manufacturer released a short instructional video, explaining the methods for correct installation of the combustion fairings and stressing the need for checking the installation once the panels are fitted.

The engine manufacturer also indicated that the design of the fairing panels was being revised to incorporate a baulking feature that will prevent the panels from being installed without the upper hooks engaged.

Qantas Airways Ltd

The operator has introduced a dual inspection requirement for cowling installation and latching. The procedure will be performed during main base maintenance visits until the manufacturer implements a mechanical baulking feature.

Australian Transport Safety Bureau safety action

As a result of the investigation, the Australian Transport Safety Bureau issues the following recommendations:

R20010230

The Australian Transport Safety Bureau recommends that Rolls Royce Ltd expedite the development, trial and implementation of a suitable engineering solution to prevent the mis-installation of combustion fairings on RB211-524 and RB211-22B engines.

Factual Information

Sequence of events

As the crew of the Boeing 747-438 applied take-off thrust to begin a flight from Sydney to Los Angeles, a noise described as "similar to an engine stall" was heard by all on the flight deck. After an immediate check of engine parameters revealed no abnormal indications, the crew elected to continue the take-off and subsequently heard no similar noises.

During the climb phase of the flight, the Cabin Services Director advised the flight crew of a small area of damage to the right outboard trailing edge flap. The first officer then inspected the area and reported that he believed that the damage was the partial delamination of the composite flap section. All engine parameters, including vibration levels were subsequently rechecked and found to be normal. After discussions with ground maintenance personnel, the crew decided to continue the flight.

On landing at Los Angeles, inspection of the aircraft by ground staff revealed the loss of both left and right combustion fairing panels from the number-three engine. Indentation and scraping damage was found on the internal surfaces of the bypass airflow nozzle behind the combustion fairing. The damage to the trailing edge flap was limited to the area immediately behind the number three engine.

On the morning following the departure, while conducting a routine runway inspection, Sydney airport staff recovered four large aircraft parts from the undershoot area of runway 34L. Further items, including small fragments of composite material, clevis couplings and metal strips, were subsequently found during a walking inspection of the runway undershoot area.

Inspection of the items by the operator's engineering personnel confirmed the items to be the missing fairing panels from the Boeing 747.

Technical examination

The ATSB examined the items recovered from the runway to determine how they separated from the aircraft. The left and right combustion fairing panels were both extensively damaged, with the larger right panel having broken into two sections. Both panels showed evidence of having forcibly struck the internal surfaces of the engine nozzle assembly before being ejected to the rear by the bypass airflow of the accelerating engine.

The fairing panels were mounted onto the engine by a row of three hooks that engaged with recessed pins on the upper panel section. When mounted, the panels latched together at the base of the engine using an adjustable hook and clevis. A study of the fairing panel mounting and latching points showed evidence that the right panel was not engaged with the upper panel at the time it was ejected from the engine. All three mounting hooks were undamaged and showed no sign of having been forcibly pulled away from the upper fairing pins. In comparison, both latches and the forward hook from the left panel showed damage consistent with the connections being overloaded and pulled apart.

Damage to the trailing edge section of the right centre wing flap was consistent with an impact with the ejected combustion fairing panels. Witness marks pointing to a forceful impact surrounded the area of damaged composite material along the edge of the flap section.

Technical analysis report number 18/01 refers to this part of the investigation and is available on the ATSB website or from the Bureau on request.

Assembly examination

The engine from which the fairing panels were lost was a Rolls-Royce RB211-524 model. The panels were part numbers UL26239 (right) and UL26237 (left), with the manufacturers illustrated parts catalogue identifying both items as made to incorporate service bulletin RB.211-72-4647. The manufacturer introduced bulletin 4647 in 1977 to combat combustion (gas-generator) fairings detaching because of incorrect fitting.

Examination of the fairing assembly during installation confirmed that it was possible to place the fairing panels in position around the engine without engaging the upper mounting hooks. The clamping action of the interlocking fire seal along the rear edge of the fairing panels allowed the items to stay in position without the support of the hooks. Latching action between the fairing panels was also unaffected.

When the panels were installed incorrectly, inspection of the upper connection points clearly showed a large gap between the upper and side fairings. Inspection of that area was difficult because of the restricted confines of the cold stream duct surrounding the panels. Platforms for use within the cold stream duct were available, however comment from maintenance personnel suggested they were rarely used. Testing the platforms showed a degree of instability in use and further restricted the access to the lower areas of the duct. Latching the fairing panels together with the platforms in place was difficult. The time taken to load, fit and then unload the platform sections, was also cited as a problem for maintenance personnel. The Boeing maintenance manual for the 747-400 aircraft requires the use of access platforms within the cold stream duct.

Maintenance records

Documents provided by the operator showed that the flight from Sydney to Los Angeles was the first flight of the aircraft following release from scheduled maintenance. That maintenance (described as an `A' check) involved several tasks that required the removal and reinstallation of the combustion fairing panels from all engines. A further review of the records relating to the work conducted on the number-three engine showed that a "panels and fairings final fitment check" line item was present in the work instructions. That action was signed-off as completed by a licensed maintenance engineer. The engine had been subsequently ground run for five minutes at idle speeds, with no noted anomalies. Check sheets for the examination of engines after ground running incorporated eight specific inspections, including a check for correct installation and latching of the fairing panels. Those checks had also been signed-off as being satisfactorily completed.

Fitting the combustion fairing panels to RB211-524 engines was the subject of several work instructions produced by the operator. The instructions referred to the operator's minor maintenance manual and the manufacturer's maintenance manual, which provided both written and visual illustrations of how the panels were to be fitted. The need for inspection of mounting hook engagement after installation was also clearly stated, with clear warnings of the potential for incorrect installation and the damage that may result. Requirements for the use of INA (integrated nozzle assembly) access platforms were also included in the latest revisions of the manual, which were issued on February 18, 2001.

Significant Factors

  1. The design of the RB211-524 engine combustion fairing allowed the individual panels to be installed without the proper engagement of the upper mounting hooks.
  2. During maintenance before the occurrence flight, the right side combustion-fairing panel was fitted to the number three engine without the mounting hooks being engaged with the upper panel section.
  3. Inspections following maintenance work and subsequently following engine ground running did not identify the incorrectly installed panel.

Analysis

Technical examination of the combustion fairing panels found that the items were released and ejected from the number three engine because of incorrect installation during maintenance activities before the flight. Evidence showed that the right side panel was not engaged with the upper panel when the items were last refitted. That situation then allowed the free movement of the fairing sections to a point where they were caught by the bypass airflow and forcibly ejected, striking the right wing outboard trailing edge flap section. The examination did not identify any deficiencies in the manufacture or maintenance of the fairing mounts or latches that could have contributed to the release.

The design of the fairing panels allowed them to be fitted to the engine and latched without the mounting hooks being engaged. Visual cues that signal a lack of hook engagement are not obvious and require specific inspection to verify correct installation. Maintenance documents for the number three engine of the incident aircraft indicated that those inspections were first carried out after work was completed and again after the engine was ground run. However, neither inspection identified the problem.

A possible reason for the failure to identify the incorrect installation of the combustion fairings was the reluctance of the operator's maintenance staff to use the cold-stream duct access platforms. Without the platforms in place, inspection of the panel mounts for the signs of incorrect installation is difficult. Platforms have not been used because of instability within the duct, time taken in fitting and limits in access to the underside of the engine core.

Summary

As the crew of the Boeing 747-438 applied take-off thrust to begin a flight from Sydney to Los Angeles, a noise described as 'similar to an engine stall' was heard by all on the flight deck. After an immediate check of engine parameters revealed no abnormal indications, the crew elected to continue the take-off and subsequently heard no similar noises.

Occurrence summary

Investigation number 200101776
Occurrence date 24/04/2001
Location Sydney, Aero.
State New South Wales
Report release date 12/02/2002
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-OJJ
Serial number 24974
Sector Jet
Operation type Air Transport High Capacity
Departure point Sydney, NSW
Destination Los Angeles, USA
Damage Minor

Beech Aircraft Corp A36, VH-NKB

Summary

A Beechcraft Bonanza A36, with the pilot and one passenger on board, departed Swan Hill at approximately 1600 on 20 April 2001. The pilot had not submitted a flight plan to Airservices Australia and did not broadcast his intentions to an air traffic control unit. However, the pilot left details of the flight at the point of departure and arranged to phone a contact on arrival at Goulburn. At about 1735 a radar trace consistent with the flight path of the aircraft was identified approaching Goulburn from Yass. The aircraft disappeared from radar 7 NM west of Goulburn at 1744, which was consistent with the flight profile of a planned descent to Goulburn. The end of official daylight was 1758. The pilot did not report to the contact by phone as planned and a search for the aircraft commenced the next morning.

The aircraft wreckage was found 4 NM to the south-west of the aerodrome. The aircraft had been flying in a direction away from the aerodrome, when it collided with dense woodland on the far side of a hill. The measured descent path of the aircraft through the trees indicated a rate of descent well in excess of that normally found in controlled flight. The aircraft was consumed by post-impact fire. The accident was not survivable.

Examination of the wreckage found no evidence of any defect in the aircraft or its systems that may have contributed to the circumstances of the accident. The pilot was appropriately licensed to operate the aircraft in day visual conditions. He had completed 4.5 hours flight training towards qualifying for issue of the night visual flight rules rating, but did not hold that rating. The aircraft was not appropriately equipped, nor was the pilot qualified for flight in instrument meteorological conditions.

At the time of the aircraft's departure from Swan Hill meteorological reports indicated the en-route weather as fine. The destination forecast indicated cloud in the vicinity of the aerodrome and a requirement to expect the possibility of holding for up to 30 minutes, for weather reasons, before a landing would be possible. Witnesses reported that at the time of the accident there was fog and drizzle in the vicinity of the hill on which the aircraft impacted.

Persons who had flown with the pilot stated that they had flown with him at night and in conditions of poor visibility. They also reported that the pilot normally flew the aircraft with the aid of a moving-map display global positioning system.

The weather conditions facing the pilot in the Goulburn area, together with fading daylight, would have deprived the pilot of a visible horizon to assist in controlling the aircraft. This would have increased the probability of spatial disorientation and a subsequent loss of control.

The circumstances of the accident were consistent with the pilot attempting to continue the flight into non-visual meteorological conditions.

Occurrence summary

Investigation number 200101729
Occurrence date 20/04/2001
Location 8 km WSW Goulburn, (NDB)
State New South Wales
Report release date 03/08/2001
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 Beech Aircraft Corp
Model 36
Registration VH-NKB
Serial number E-933
Sector Piston
Operation type Private
Departure point Swan Hill, VIC
Destination Goulburn, NSW
Damage Destroyed

Boeing 767-204, VH-RMO

Safety Action

Local safety action

As a result of their investigation into the incident, the operator implemented the following changes:

1. Introduced new task cards into all Heavy Maintenance B767 major check packs that require the routine deactivation of all door slides at the start of every check and the return to normal configuration on completion.
2. Amended independent inspection requirements to clearly indicate that all parts of the appropriate maintenance manual slide installation task are included.
3. Amended the section of the Flight Readiness Schedule to include door slides for correct flight configuration (girt bar and inflation cylinder regulator safety pin correctly located).
4. Commenced implementing mandatory attendance of the company's Human Factors/Error and Maintenance Resource Management program for all staff.

In addition to these changes, the operator has initiated or completed the following actions related to this occurrence:

1. Reviewed the practice of Senior LAMEs raising discrepancy/supplementary cards for work that has not been performed or supervised by them personally. Additionally, a study is in progress to attempt to identify possible improvements in documentation procedures to include staged signoffs of work completed.
2. Reviewed the supervision level for apprentices and AMEs working on B767 aircraft during Heavy Maintenance checks and briefed staff on the need for focused supervision of less experienced engineers.
3. Notified all Heavy Maintenance staff of the requirement to accurately record all maintenance actions performed, using the appropriate document.

RECOMMENDATIONS

As a result of this investigation, and occurrence investigation number 200101866, the Australian Transport Safety Bureau has identified a safety deficiency related to Boeing jet aircraft cabin door escape slide maintenance documentation. The ATSB therefore issues the following recommendation.

R20010168

The Australian Transport Safety Bureau recommends that the Civil Aviation Safety Authority conduct a review of maintenance documentation for the Australian Boeing jet aircraft fleet to ensure completeness of cabin door escape slide deactivation and reactivation maintenance procedures.

Significant Factors

1. Maintenance documentation for escape slide activation/deactivation and inspection was inadequate.
2. Maintenance personnel utilised unauthorised short cuts and work arounds.
3. Maintenance personnel signed off inspections and installations not yet completed.
4. Line maintenance personnel did not initially detect the door/slide anomaly.

Analysis

The four escape slides were deactivated during the 2C check without any record on approved maintenance documentation as per requirements of the Heavy Maintenance Manual. The apprentice who deactivated the escape slides did not personally record the details of the maintenance performed. The senior LAME supervising the apprentice later noted the maintenance performed by the apprentice in the aircraft documentation. The entry did not reflect the total scope of the work preformed by the apprentice. Supervision of the apprentices involved was inadequate to detect paperwork and maintenance irregularities at the time they occurred.

Unrelated work in the area of the slides interrupted completion of the slides installation before removal of the aircraft from the hangar for engine runs. Delays in completion of the 2C inspection resulted in maintenance personnel deviating from accepted practices to return the aircraft to flight status as quickly as possible to avoid further slippage in the maintenance schedule.

The independent inspection requirements for escape slides of the B767 Flight Readiness Schedule were misinterpreted as there was no specific requirement to check girt bar installation. The check of door mounted escape slides on the B767 Flight Readiness Check List did not include a check of the girt bar. This led to maintenance personnel not noting the stowage of the girt bars.

Lack of a thorough inspection by line maintenance personnel following a report from cabin crew of problems with the bustle at main cabin door L1, resulted in continued operation of the aircraft with inoperative slides. Inadequate troubleshooting by line maintenance personnel following the discovery of the discrepancy with the slide girt bar at cabin door L1, resulted in continued operation of the aircraft with additional inoperative slides.

Note: This report is specific to the issues of girt bars on Boeing 767 aircraft. A separate investigation examining Class A aircraft issues was ongoing at the time of printing this report.

Summary

Following the Boeing 767 (B767) aircraft's second flight after scheduled maintenance, a pilot maintenance log entry noted that the cabin door L1 slide bustle was hanging down. A line engineer on duty examined and certified that the cause was a weak cable spring. The discrepancy was then placed on deferred maintenance as it was not considered to be an airworthiness defect. The following day, prior to departure, the cabin crew of the aircraft reported the cabin door L1 (forward entry door) bustle was lower than normal. Inspection revealed that the girt bar was not attached to the escape slide girt bar carrier, but was instead in the stowed for maintenance position, rendering the slide inoperative. The line engineer on duty correctly installed the girt bar, thereby returning the L1 door escape slide to operational capability. No maintenance log entry was made concerning the discrepancy, or of the corrective actions.

When maintenance personnel conferred following the L1 door escape slide girt bar rectification, a decision was made to inspect the remaining aircraft door slides for condition. The inspection revealed that cabin doors R1 (forward service door), R2 (rear service door), and L2 (rear entry door) emergency escape slides were inoperative, with the door girt bars also in the stowed position.

Consequently, during 8 and 9 April 2001, the aircraft was operated seven sectors with four cabin door mounted escape slides inoperative. During 9 April 2001, the aircraft was operated one sector with three slides inoperative. If required, the cabin crew could not have successfully activated the escape slides of those doors, nor the automatic opening of the doors during those flown sectors.

B767 cabin door configuration

The cabin door configuration of this aircraft was one forward door and one rear door per side. The doors were arranged in sequential order, numbered from the nose of the aircraft. The doors were identified as per side by lettering indicating `L' for the left side of the cabin looking towards the nose, and `R' for right.

Previous maintenance

Further investigation revealed that the last known maintenance of the escape slides, bustles, and girt bars of doors R1, R2, L1, and L2 was performed sixteen days earlier, during a recent 2C scheduled maintenance check. The C check on B767 aircraft, a major scheduled maintenance check, was performed at 6,000 flight hour intervals, and normally planned for 30 days elapsed time (total days out of service). The incident aircraft was out of service for the 2C check for 41 days.

During that maintenance, the escape slide bustles of doors L1, L2, R1, and R2 were disabled and removed by an apprentice Aircraft Maintenance Engineer (AME) under supervision, to allow repainting, other maintenance in the area, and zone inspections. During disabling and removal of the bustles, the girt bars were removed from the carriers and stowed using special straps on the side of the slide packs.

Door mounted slide normal operation

During normal operation, door arming by the cabin crew would lock the girt bar carrier to the aircraft floor fittings. The girt bar would engage the girt bar carrier, whether the slide was ARMED or DISARMED. The ARMED or DISARMED status of the door-mounted slides was indicated to the cabin crew by witness marks, visible at floor level. The arming witness marks reflected the girt bar carrier position in the floor fittings, not the location of the girt bar itself. Thus, the ARMED indication presented to the cabin crew was the same, whether the girt bar was properly installed in the girt bar carrier or stowed on the slide pack.

When a cabin door was unlocked from the inside while in the ARMED condition, the girt bar (engaged with the carrier) initially caused the slide to release from the door. The unladen door would then open under the influence of heavy springs. The subsequent action of the slide pack falling out of the doorway activated the slide inflation sequence.

Door mounted slide operation with girt bar stowed on the slide pack

With the girt bar stowed on the slide pack, each door would have unlocked if opened from the inside in the ARMED condition, however the girt bar carrier would have remained (disconnected from the door) in the floor fittings. The slide pack would have remained intact and attached to the door. The doors would have needed opening manually (as though disarmed), as the emergency auto-opening feature of the cabin door, before slide deployment, relied on the weight of the slide releasing from the door as the door was unlocked. Manual operation was only applicable if the slide had released from the door, but failed to inflate.

Maintenance documentation (removal of the escape slide)

The maintenance facility's normal practice was to use the company's Maintenance Supplementary Report (MSR) form to document tasks involving removal of items from an aircraft for access and inspection purposes. The removal of four escape slide bustles was noted on the aircraft's MSR form for the maintenance event, however, the apprentice who completed the removal of the bustles did not personally document details of the removal in the MSR form. The apprentice did annotate on a Supplementary Report Card (SRC) the bustles removal in accordance with the company's maintenance manual procedures.

The senior Licensed Aircraft Maintenance Engineer (LAME) responsible for the cabin during the scheduled inspection, and supervising the apprentice, stated that his normal practice was to annotate in the Heavy Maintenance Discrepancy Report (HMDR) form, deactivation of the escape slides. On that occasion, he noted the removal of the slide bustles but not the deactivation of the escape slides. There was no evidence that a hand-over log was employed documenting the work.

Installation of the escape slide

Following completion of the zone maintenance in the area of the slides, another apprentice was tasked with reinstallation of the slide bustles to allow the aircraft to be moved outside for engine runs. The engine runs were normally performed three days before maintenance check completion to identify and resolve any engine related anomalies. Normal Heavy Maintenance practices required the slides be installed and operational during engine runs. The slide bustles, including the girt bars, were not completely installed because of on-going work in the area. It was reported that the aircraft's inspection completion was behind schedule by approximately one week.

The bustles of the four doors were partially installed by a second apprentice and annotated on the SRC as completed in accordance with the applicable maintenance manual section. The installation was not completed as per the maintenance manual at that time, as the girt bars were still stowed and the inflation cylinder regulator safety pins were still fitted. No other documentation was utilised to annotate the partial installation.

Post maintenance inspection of the escape slide

According to aircraft maintenance documentation, two LAMEs conducted independent inspections of the slides following maintenance to the slide during the scheduled check. Both conducted and certified the inspection with the knowledge that slide R1 was not yet fully operational. An independent inspection was not carried out for maintenance actions performed on escape slide bustles at the L1, L2 and R2 doors. No additional entries were annotated in the aircraft documentation to note the non-operational condition of the slides.

Prior to release from the 2C check, the B767 Flight Readiness Schedule, an engineering check list, was used to ensure aircraft completion. The check list contained a requirement to check over-wing emergency exits for correct arming, but for door mounted slides the inspection was only to verify that the escape slides were installed.

Human factors issues

The LAME responsible for cabin certification during the 2C check, reported that this was the first time he had been tasked with such duties.

Occurrence summary

Investigation number 200101606
Occurrence date 09/04/2001
Location Sydney, Aero.
State New South Wales
Report release date 16/11/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Serious Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 767
Registration VH-RMO
Serial number 23807
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination Sydney, NSW
Damage Nil

Boeing 737-476, VH-TJX

Safety Action

Local safety action

As a result of the accident, the operator implemented the following safety actions:

1. The Engineering and Maintenance Procedures Manual has been amended to include an instruction requiring drivers to have a marshaller present during towbar hook ups and for the marshaller to stand to one side of the vehicle during this operation.

2. The Engineering and Maintenance Procedures Manual has been amended to include a requirement for drivers to operate tugs from the seated position in those tugs designed for operation from this position.

3. An evaluation of the handling characteristics of the tug has been conducted with a view to an assessment as to the suitability of the tug for further operations.

4. Anti-slip paint has been applied to the brake pedal and has been incorporated into the system of maintenance.

5. An external overhead mirror has been fitted to enable drivers to view the towbar hitch point from the seated position in the control cabin.

6. An assessment has been made as to whether other tugs used by the operator require modification with anti-slip paint and external overhead mirrors.

7. A lockout switch has been fitted so that the transmission selector cannot be moved from the neutral position unless pressure is applied to the brake pedal.

8. A recurrent proficiency program has been implemented for drivers who have not driven a particular type of tug for 6 months.

In addition, the operator is assessing the feasibility of fitting transmission selector lockout switches to other tugs used by the operator, which do not have these switches fitted as standard equipment.

Analysis

Concerned that the departure of the aircraft was about to fall behind schedule, the engineer decided to connect the towmotor to the towbar as a single person operation. That decision, combined with the design of the towmotor, led the engineer to operate the towmotor from a standing position. The subsequent movement of the towmotor was consistent with the driver inadvertently placing his foot on both control pedals simultaneously.

Summary

A Boeing 737-476 aircraft was in the final stages of preparation for an 0810 EST scheduled departure from Melbourne. It was the aircraft's first flight of the day. The ground engineer had completed the pre-flight and other assigned pre-departure tasks. There was little else for him to do prior to his duties for the pushback which included assisting the ramp towmotor driver to connect the towbar to the towmotor and walk out with the aircraft. The flight crew had started the Auxiliary Power Unit (APU) and were completing the Before-Start Checklist in preparation for pushback.

The towbar was delivered by ramp personnel at 0803 and was connected to the aircraft nose landing gear by the engineer. At 0805, cargo loading was still in progress in both the forward and rear cargo bays. The engineer was aware that the towmotor should only be driven by the rostered ramp towmotor driver who was still involved with the loading of the aircraft. Concerned that the departure of the aircraft was about to fall behind schedule, he decided to connect the towmotor to the towbar himself.

The engineer moved the towmotor close to the towbar, but stopped when he noticed that the towbar was at the wrong height for connection. He then left the cab, with the towmotor's engine running, to correct the towbar height. While re-adjusting the towbar, he heard the towmotor engine shut down. He reported that he then climbed back into the towmotor, restarted the engine, and attempted to drive forward the remaining 10 cm required for connection.

At that time the towmotor appeared to him to move forward "...relentlessly..." and collided with the aircraft. He indicated that he had applied the brakes and selected reverse gear, without success. He then vacated the cabin of the towmotor across the deroofed front of the vehicle.

The flight crew indicated that they heard and felt a "...big thump..." which continued and shook the aircraft for about 4-5 seconds. The pilot in command advised the cabin crew to "...brace..." and noticed the towmotor wedged under the aircraft nose. He assessed that there was no danger to the aircraft and ordered that the passengers be disembarked normally through the forward door via the aerobridge, which was still in place. He shut down the flight deck systems, set the park brake, but left the APU running to power the hydraulics and disembarked to view the extent of the damage.

The aircraft had sustained substantial damage to the radome, forward pressure bulkhead, forward fuselage skin and nose landing gear doors.

The engineer had been employed by the operator for more than 26 years and was highly regarded as a Licensed Aircraft Maintenance Engineer (LAME) and company employee. Supervisors indicated that the engineer was very cooperative and willing to assist ramp staff at all times to despatch aircraft on schedule.

At the time of the accident, the engineer was on the first day of a shift rotation, having been off-duty for the preceding three weeks.

The engineer held a current ramp driver's licence and had considerable recent experience towing aircraft using another towmotor type. He had last driven the accident towmotor about 6 months previously.

Towmotor and towbar information

The towmotor was designed specifically for B737 use. It had last undergone maintenance action on 5 March 2001. According to the operator's maintenance staff, the accident towmotor was used only on the ramp as it was unsuited for maintenance purposes. It was the only one of its type used by the operator.

The design of the towmotor was such that the towbar and connection point at the front of the vehicle could not be seen from the driver's seated position. Towbar connection was a two-person operation. Any attempt by a single person to connect the vehicle and the towbar, involved the driver having to stand up and lean over the steering wheel to view the operation. From a standing position, it was possible for the driver to place a foot over both the accelerator pedal and the brake pedal simultaneously.

The cabin forward structure had been torn upwards and rearwards during the initial contact with the aircraft. The rear left corner of the cabin structure was forced down through the vehicle's upper body panel by the weight of the aircraft's nose. Inspection of the towmotor found no mechanical fault that could have contributed to the accident.

The towbar for the Boeing 737 aircraft underwent a complete service on 28 March 2001 and had been correctly connected to the nose landing gear strut of the aircraft. Impact from the towmotor sheared the towbar's rear shear pin, which allowed the bar to swivel out of the way, pivoting on the remaining shear pin, as the towmotor drove forward into contact with the aircraft. The towbar was inspected and found to have been serviceable at the time of the accident.

Aircraft pushback procedures

Aircraft pushback procedures at the time of the accident were contained in the operator's Ramp Standard Operating Procedures (SOP). The SOP stated that the towbar was to be delivered to the aircraft by ramp personnel, then connected to the nose landing gear by the engineer. Connection to the towmotor was to be accomplished by the rostered ramp towmotor driver, with the assistance of the engineer. Line engineers normally towed the aircraft for maintenance purposes only. In addition, the SOP stated:

"Use a marshal (usually the engineer) when manoeuvring for hook up to the tow bar when it is attached to the aircraft. Do not stand up to see the hitch point."

The operator's Engineering and Maintenance Procedures Manual stated that:

"...Prior to push-out operation, the engineer will...(2) Connect the towbar and towmotor by front or rear connection as appropriate..."

A ramp driver's licence was valid for a 12 month period. Renewal was devolved to airline operators by the airport owner and consisted of a written examination covering rules, procedures, airfield speed limits and ATC communications and light signals. No driver refresher training was conducted. Company towmotor drivers who were qualified to tow aircraft on the ramp were to conduct towing operations in accordance with their respective company SOP.

Occurrence summary

Investigation number 200101409
Occurrence date 01/04/2001
Location Melbourne, Aero.
State Victoria
Report release date 04/12/2001
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 737
Registration VH-TJX
Serial number 28150
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination Hobart, TAS
Damage Substantial

Aero Commander 500-S, VH-UJB, near Cairns, Queensland, on 10 April 2001

Significant Factors

The aircraft was flown at an altitude that was insufficient to ensure terrain clearance.

Analysis

Radar data recorded by Air Traffic Services and witness reports indicated that the aircraft was flying straight and level and maintaining a constant airspeed. Therefore, it is unlikely that the aircraft was experiencing any instrumentation or engine problems.

Why the pilot continued flight into marginal weather conditions at an altitude that was insufficient to ensure terrain clearance, could not be established.

Summary

A Shrike Commander 500S aircraft departed Cairns airport at 0707 Eastern Standard Time (EST) on a charter flight to Hicks Island. The aircraft was being operated under the Instrument Flight Rules (IFR) and the expected flight time was 2 hours. Shortly after take-off the pilot requested an amended altitude of 4,000 ft. He indicated that he was able to continue flight with visual reference to the ground or water. Air Traffic Services (ATS) issued the amended altitude as requested.

The IFR Lowest Safe Altitude for the initial route sector to be flown was 6,000 ft Above Mean Sea Level (AMSL).

Data recorded by ATS indicated that approximately 13 minutes after departure, the aircraft disappeared from radar at a position 46NM north of Cairns. At the last known radar position the aircraft was cruising at a ground speed of 180 kts and at an altitude of 4,000 ft AMSL. An extensive search located the wreckage the following afternoon at a location consistent with the last known radar position, on the north-western side of Thornton Peak at an altitude of approximately 4,000 ft (1219 metres) AMSL. The aircraft was destroyed by impact forces and post-impact fire. The pilot and three passengers received fatal injuries.

Thornton Peak is the third highest mountain in Queensland and is marked on topographic maps as 4,507 ft (1,374 metres) in elevation. Local residents reported that the mountain was covered by cloud and swept by strong winds for most of the year.

The aircraft had been observed by witnesses approximately two minutes prior to impact cruising at high speed, on a constant north-westerly heading, in a wings level attitude and with flaps and landing gear retracted. They stated that the engines appeared to sound normal.

Wreckage and impact information

ATSB investigators were unable to attend the accident site due to the prevailing weather conditions. However, they were able to view video footage of the wreckage which had been recorded by the search and rescue helicopter crew at the time the wreckage was located. The footage displayed evidence of the presence of both wings and the tail section of the aircraft and indicated a straight and level flight attitude at the time of impact. Damage to the aircraft structure, engines and propellers appeared extensive. There appeared to have been a limited post-impact fire. The aircraft Emergency Locator Transmitter (ELT) did not activate.

Pilot information

The pilot in command held a Commercial Pilot (Aeroplane) Licence and a Command Multi-Engine Instrument Rating. He had been employed by the company for approximately seven years and held the position of North Queensland Base Manager. At the time of the accident the pilot had accumulated a total 9,680 flying hours including 7,144 on multi-engine aircraft and 2,402 hours on Shrike Commander aircraft. He had flown 117 hours in the previous 90 days. He was reported to have been fit and well rested prior to the flight.

Aircraft information

The aircraft had undergone scheduled maintenance on 22 March 2001. A major inspection and overhaul had been completed on 29 September 2000, with the airframe completely stripped and painted and all components removed and reinstalled. The aircraft was considered capable of normal flight prior to the accident.

Meteorological information

The Bureau of Meteorology Area Forecast at the time of the accident indicated isolated showers tending to scattered in the east over the sea, coast and adjacent ranges south of Princess Charlotte Bay, with isolated fog patches from 0400 until 0800 EST. Winds were south-easterly at 20 kts. Significant cloud consisting of Cumulonimbus, Stratus and Cumulus, was forecast from 2,500 to 40,000 ft. Forecast weather conditions included showers, thunderstorms and fog, with visibility of 2,000 m in thunderstorms, 3,000 m in showers and 900 m in fog. Turbulence was predicted to be occasionally moderate below 5,000 ft over the coast and ranges south of Cooktown.

The Terminal Area Forecast (TAF) for Cairns indicated wind from 130 degrees magnetic at 13 kts, visibility greater than 10 km, showers and rain, scattered cloud at 2,500 ft, scattered cloud at 4,000 ft and conditions deteriorating intermittently for periods up to 30 mins to visibility 4,000 m in showers and rain, scattered cloud at 1,000 ft and broken cloud at 1,800 ft.

The TAF for Cooktown (48 NM north of the accident site) indicated wind from 120 degrees magnetic at 14 kts, visibility greater than 10 km, showers and rain, scattered cloud at 2,000 ft, scattered cloud at 4,000 ft and conditions deteriorating intermittently for periods up to 30 mins to visibility 4,000 m in showers and rain, scattered cloud at 1,000 ft and broken cloud at 2,000 ft.

Actual meteorological observations for Cairns and Cooktown at the time of the accident indicated winds of 170 degrees at 8 kts and 120 degrees at 6 kts respectively. Cloud observed at Cairns was 2 octas Cumulus at 2,500 ft and 3 octas Stratocumulus at 4,000 ft. Under the influence of the prevailing moist south-easterly airstream, the ranges adjacent to the coast would have been covered by low cloud.

The Australia Advanced Air Traffic System (TAAATS) has a Minimum Safe Altitude Warning System (MSAW) as part of its normal operation. MSAW operates within defined areas normally associated with operations in the terminal area within controlled airspace. The system uses off-line defined topographical data to warn controllers when aircraft are likely to operate close to terrain within controlled airspace. The impact area was outside controlled airspace and not in an MSAW defined area.

In addition, in accordance with the Manual of Air Traffic Services, when pilots in command accept terrain clearance visually, air traffic controllers do not respond to MSAW alerts.

Occurrence summary

Investigation number 200101537
Occurrence date 10/04/2001
Location 85 km N Cairns, Aero.
State Queensland
Report release date 06/02/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Aero Commander
Model 500
Registration VH-UJB
Serial number 3152
Sector Piston
Operation type Charter
Departure point Cairns, QLD
Destination Hicks Island, QLD
Damage Destroyed

Piper PA-31-350, VH-LTW

Summary

The pilot of the Piper Chieftain reported that at the top of descent he noticed that the left engine began to run roughly. Initial checks showed no evidence of a problem and the pilot began to troubleshoot. Approximately 30 seconds after the initial onset of vibrations, the pilot noticed that the left engine oil pressure and power significantly decreased before the engine failed. The pilot shut the engine down and feathered the propeller in accordance with emergency procedures. The pilot broadcast a PIN to Melbourne Air Traffic Control advising of the situation and that his intention was to continue to Devonport. After arriving in the circuit area the pilot ensured that the Rescue Fire Fighting Service was in attendance and that he had briefed the passengers, before landing the aircraft without further incident.

A post flight engineering inspection revealed that a number 2-cylinder connecting rod bolt had failed allowing the rod to puncture the left engine crankcase in two locations.

The failed components were examined by the ATSB technical analysis section. It was found that the number 2 connecting rod failure was the result of fatigue cracking of the connecting rod big-end bearing housing.

The fatigue cracking had initiated and developed due to abnormal loads arising from the loss of the bearing shell material from within the connecting rod big-end housing. The connecting rod bolt failure then occurred due to bending overload, which resulted from the fatigue cracking and separation of the opposite side of the big-end bearing housing.

As at 11 September 2001, the ATSB was examining ten engines from PA 31 aircraft types as part of the ongoing investigation 20002157. The engine in this occurrence was one of the ten being examined, however insufficient evidence was available from the items examined in this occurrence to enable a determination of the mechanism of the big-end bearing failure.

Occurrence summary

Investigation number 200101405
Occurrence date 26/03/2001
Location 59 km WNW Devonport, (NDB)
State Tasmania
Report release date 21/09/2001
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-LTW
Serial number 31-8152025
Sector Piston
Operation type Air Transport Low Capacity
Departure point King Island, TAS
Destination Devonport, TAS
Damage Nil

Amateur Built Lancair 320, VH-DNO

Summary

The owner of Lancair, VH-DNO, was in the process of selling his aircraft. He had arranged to meet some prospective purchasers at Mildura, and had flown from Maroochydore that morning so that the purchasers could inspect and fly the aircraft with him. He started the flight early in the morning and arrived in Mildura at lunch time. The day was warm and, as the top of the cockpit was transparent, the cockpit would also have been very warm. The pilot stated that he had consciously limited his fluid intake during the flight as the duration of each leg was fairly long.

Two people who had travelled to Mildura for the aircraft inspection were considering purchasing the aircraft together. When the vendor arrived at Mildura, he joined the two prospective purchasers in the airport terminal, where he drank some water and ate some fruit. As they discussed the aircraft, one of the purchasers emphasised his interest in the aircraft's take-off and landing performance and low speed handling characteristics. After about half an hour, the purchasers agreed which one would go for the first test flight and they went out to the aircraft. The vendor sat in the left (command) seat and the purchaser sat in the right (passenger) seat; both seats had functioning flight controls.

Approximately half an hour later, a witness who was working in a vineyard saw the aircraft flying straight and level, with power changing regularly from a high power setting to idle. A short time later, the witness looked up again when an unusual noise attracted his attention. He saw the aircraft descending in a spin and disappear behind a hill. Shortly after, he heard a sound consistent with the aircraft impacting the ground.

The aircraft had impacted the ground at high speed, in straight flight, with wings level and a steep nose down angle. Both occupants received fatal injuries. No indication was found of any pre-existing defect in the aircraft or the engine prior to the accident. The landing gear and the flaps were extended at the time of the accident.

The circumstances of the accident were consistent with a loss of control during a demonstration of the handling characteristics of the aircraft at low speed with landing gear and flaps extended. The aircraft entered a spin for reasons that could not be determined. The circumstances were consistent with the spin rotation having been arrested and the aircraft impacting the ground as it was accelerating during the pull out from a dive at the end of a spin recovery.

Occurrence summary

Investigation number 200101082
Occurrence date 13/03/2001
Location Nangiloc
State Victoria
Report release date 13/06/2001
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 Amateur Built Aircraft
Model Lancair
Registration VH-DNO
Serial number Q058
Sector Piston
Operation type Private
Departure point Mildura, VIC
Destination Mildura, VIC
Damage Destroyed

Cameron Balloons Ltd V-77 , VH-LPO

Safety Action

As a result of this investigation, the Australian Transport Safety Bureau issues the following recommendations.

R20010133

The Australian Transport Safety Bureau recommends that the Civil Aviation Safety Authority, in conjunction with appropriate specialist organisations, develop and promulgate requirements that specify which fuel cylinder fittings are suitable for use in balloons, and suitable configurations for those fittings.

R20010134

The Australian Transport Safety Bureau recommends that the Civil Aviation Safety Authority ensure that balloon owners and operators identify and remove gas tank fittings that are not suitable for balloon operations.

Factual Information

Sequence of events

The balloon pilot and his two passengers were conducting a private flight as part of the Canberra balloon festival. The balloon's equipment included three aluminium liquefied petroleum gas (LPG) fuel cylinders, dual burners, three radios, a motorcycle-type lead-acid battery, an altimeter and a variometer. After completing a normal flight, the pilot prepared to land the balloon on an area of parkland. This area was relatively small, with large trees on the approach and a street and houses in the direction of flight. Following the touchdown, as the balloon envelope continued to travel, the basket gradually tipped over and the pilot pulled the ripline to deflate the envelope. At about that time, the occupants of the basket noticed a fireball in the basket and immediately evacuated. Witnesses described the flames as yellow. The pilot stated that he let go of the ripline and allowed the balloon to ascend, deciding that it was safer for the fuel cylinders to be in the air than on the ground surrounded by bystanders. Witnesses heard an explosion and saw an object fall from the remains of the basket. The fire continued to burn, and subsequently consumed the wicker basket and damaged the lower panels and skirt of the envelope. Debris from the balloon fell across three suburbs and damaged several houses. The remains of the balloon were subsequently found 1.6 km from the initial landing point.

The pilot of the balloon was wearing a hat, a short-sleeved cotton shirt, trousers, gloves and shoes. He sustained serious burns to his forearms, face and neck. The male passenger was wearing a woollen lumberjack-style long-sleeved shirt, jeans, gloves, boots, sunglasses and a hat. He sustained minor burns to his face and wrists and was the only occupant not admitted to hospital. The female passenger was wearing running shoes, three-quarter length pants, gloves and a long-sleeved top which did not tuck into the waistband of her pants. She sustained serious burns to her shins and stomach.

Wreckage examination

An examination of the wreckage of the balloon established that two aluminium fuel cylinders were each connected to one of the two burners. One tank was connected by both the vapour feed line and the liquid feed line, while the other was only connected by the vapour feed line. Both pilot-light valves were on, the cross-feed valve was off and both the liquid and vapour offtake valves on both fuel cylinders were on. It was also noted that a male connector fitting had broken off flush with the top of the threaded portion of the body of the corresponding fuel cylinder liquid offtake valve.

Further examination of the broken fitting showed that it had been partially fractured when the fire developed. The fracture was sufficiently large to allow the uncontrolled escape of LPG into the balloon's basket. The fracture surfaces indicated that the fire was no longer burning near the fracture at the time the fitting broke away completely. The fitting had fractured in a downward direction, and there was no evidence of fatigue or pre-existing defects.

One aluminium fuel cylinder was found along the debris trail between the initial landing site and the final location of the remains of the balloon. This cylinder had failed because of a single ductile rupture of the upper shell section, characterised by a large bulged area, outwardly turned fracture lips and extensive blackening and sooting around the rupture.

Pilot light usage

The balloon manufacturer's Flight Manual section 4.6 'Landing', stated that the pilot light should be turned off before touchdown. Some balloon pilots indicated that they sometimes left the pilot lights on for landing if they were certain that the balloon basket would not tip over, allowing them to conduct a go around if required. Once the pilot lights were turned off, if insufficient height was available to relight the pilot lights, a pilot would normally be prevented from conducting a go around before the balloon touched down.

Fuel cylinder fitting selection

The broken fitting consisted of a Rego 8101P5 service valve coupled to a 7141M check connector. With this configuration, the assembly extended outside the fuel cylinder guard ring.

aair200101065_001.jpg
aair200101065_002.jpg

A comparison of the Rego 8101P5/7141M combination liquid offtake valve (left), and the Rego 8180 valve (right), and their relationship to the fuel cylinder guard ring

The balloon manufacturer's maintenance manual stated that "only factory supplied parts and materials are permitted to be used for repair or maintenance actions". The manufacturer advised that they previously supplied the Rego 8180 valve, but now supplied the BMV 344 handwheel-type liquid offtake valve in place of the Rego 8180 valve. The BMV valve was similar to the Rego 8180 valve. Balloon industry personnel suggested that while the Rego 8180 valve was the most widely used fitting, the Rego 8101P5/7141M combination was also relatively widely used in ballooning applications.

While the balloon manufacturer's documentation provided guidance regarding selection of fuel cylinder fittings, general practice among balloonists was for gas supply companies to replace, if required, fuel cylinder fittings during the mandatory 10-yearly cylinder inspection. Gas supply company personnel generally have extensive experience and knowledge regarding fuel cylinder maintenance, but they do not normally have much involvement in the aviation industry. They are not provided with detailed guidance regarding the appropriate selection and configuration for fuel cylinder fittings for aviation applications.

The investigation did not establish who had installed the Rego 8101P5/7141M combination liquid offtake valve.

Analysis

The intensity, size and rapid onset of the fire after the balloon landed suggested that a rapid, uncontrolled leak of LPG had occurred. The most likely source of the LPG leak was the fractured liquid offtake valve. It is also likely that the fracture occurred during the landing. The yellow flames reported by witnesses and the sooting of the ruptured cylinder suggest that the fire was fuel-rich, consistent with a high-volume gas or liquid fuel supply.

The position of the pilot light valves indicated that the pilot lights were on during the landing. Each of the radios or the battery could have provided an ignition source, but it is most likely that the pilot lights ignited the leaking LPG. Had the pilot lights been turned off prior to the landing, in accordance with the flight manual and standard ballooning practice, it is unlikely the leaking gas would have ignited.

The condition of the ruptured fuel cylinder indicated that it had failed as a result of flame impingement and subsequent softening of the aluminium shell. The explosion of the cylinder was therefore a consequence of the fire, rather than contributing to its development.

The length of the broken fitting provided significant leverage that would have required only a relatively small force to be applied before the fitting broke. There was also limited protection for the fitting because it extended significantly beyond the fuel cylinder guard ring. While the Rego 8101P5/7141M combination liquid offtake valve may have been appropriate for some applications, it was not appropriate for aviation. A firm or tip over landing could have resulted in the fitting being bumped or otherwise subjected to stress by occupants or equipment moving around.

The occupants of the balloon generally sustained burns to exposed areas of skin. Had they been wearing natural fibre clothing that more effectively covered these exposed areas, the extent of their burns would almost certainly have been reduced.

The investigation revealed that fuel cylinder fittings similar to the fitting that failed are relatively common in the ballooning industry in Australia. This suggests that the ballooning industry as a whole is not sufficiently aware of the safety implications of fittings extending significantly beyond the fuel cylinder guard ring.

The selection of suitable fittings for fuel cylinders in balloons requires the expertise of both the gas supply industry and the aviation industry. Both industries have specific requirements related to fuel cylinder fitting selection and configuration that may not be completely understood by the other.

Summary

The balloon pilot and his two passengers were conducting a private flight as part of the Canberra balloon festival. The balloon's equipment included three aluminium liquefied petroleum gas (LPG) fuel cylinders, dual burners, three radios, a motorcycle-type lead-acid battery, an altimeter and a variometer. After completing a normal flight, the pilot prepared to land the balloon on an area of parkland. This area was relatively small, with large trees on the approach and a street and houses in the direction of flight. Following the touchdown, as the balloon envelope continued to travel, the basket gradually tipped over and the pilot pulled the ripline to deflate the envelope. At about that time, the occupants of the basket noticed a fireball in the basket and immediately evacuated. Witnesses described the flames as yellow. The pilot stated that he let go of the ripline and allowed the balloon to ascend, deciding that it was safer for the fuel cylinders to be in the air than on the ground surrounded by bystanders. Witnesses heard an explosion and saw an object fall from the remains of the basket. The fire continued to burn, and subsequently consumed the wicker basket and damaged the lower panels and skirt of the envelope. Debris from the balloon fell across three suburbs and damaged several houses. The remains of the balloon were subsequently found 1.6 km from the initial landing point.

The pilot of the balloon was wearing a hat, a short-sleeved cotton shirt, trousers, gloves and shoes. He sustained serious burns to his forearms, face and neck. The male passenger was wearing a woollen lumberjack-style long-sleeved shirt, jeans, gloves, boots, sunglasses and a hat. He sustained minor burns to his face and wrists and was the only occupant not admitted to hospital. The female passenger was wearing running shoes, three-quarter length pants, gloves and a long-sleeved top which did not tuck into the waistband of her pants. She sustained serious burns to her shins and stomach.

Occurrence summary

Investigation number 200101065
Occurrence date 10/03/2001
Location Evatt
State Australian Capital Territory
Report release date 20/08/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Fire
Occurrence class Accident
Highest injury level Serious

Aircraft details

Manufacturer Cameron Balloons Ltd
Model Viva
Registration VH-LPO
Serial number 1862
Sector Balloon
Operation type Ballooning
Departure point Parkes, ACT
Destination Evatt, ACT
Damage Destroyed

Piper PA-28-181, VH-MIZ

Safety Action

Local safety action

Airservices Australia has amended Local Instructions to more clearly indicate the responsibility of the ADC to ensure that, prior to issuing a take-off clearance, the callsign of an aircraft is read back by the TMA controller as part of the acknowledgment of the auto release coordination.

Local Instructions have also been amended to ensure voice coordination between the TMA controller and the ADC is more specific when clearing an aircraft for an instrument approach to other than the system runway. Specifically, revised instructions require that voice coordination take place "immediately prior to the aircraft being cleared for final".

Airservices Australia Advised the ATSB that it is:

a. taking advantage of opportunities that arise from time to time to provide controllers with familiarisation visits, but that a formalised familiarisation program was not currently possible.

b. reviewing the arrangements for booking training instrument approaches at Canberra.

Significant Factors

  1. The TMA controller and the ADC did not mutally agree on the use of the reciprocal runway for a training ILS apprach after the traffic sequence was changed.
  2. The TMA controller and the ADC did not use voice coordination to revise the sequencing of the Archer
  3. The TMA controller did not use aircraft callsigns as an acknowledgment of auto-release coordination.
  4. The ADC did not seek an acknowledgment using callsigns from the FMA controller during auto-release coordination

Analysis

The Archer was allowed to depart from Canberra to undertake two training ILS appraches when up to seven Regular Public Transport departures were pending from the reciprocal runway. While the ILS booking system was not intended as a traffic management tool, use of the system for that purpose may have assisted in planning the traffic situation more effectively.

While the Archer was being vectored for the ILS approach, coordination took place between the ADC and the TMA controller for two departures and then, by mutual agreement, for the Archer to conduct the first training ILS approach. The TMA controller was subsequently advised that a further three aircraft were taxiing that had priority and to hold the Archer out. There was no further discussion between the controllers as to when the Archer would be re-sequenced for the ILS approach. From that point in time there was no mutual agreement between the controllers for the use of the reciprocal runway. Moreover, no voice coordination regarding the Archer, as required by local instructions, took place subsequent to the first occasion when mutual agreement had been achieved.

The readback of a callsign as part of the acknowledgment of any coordination is an important defensive measure that helps minimise the likelihood of any misunderstanding between controllers. In this incident, there was no acknowledgment by callsign from the TMA controller during the auto release coordination and the ADC sought notice. Use of the correct acknowledgment and/or a challenge from the ADC to obtain the correct acknowledgment would have likely reiterated that KDQ was in the group of aircraft about to be released, thereby ensuring that the TMA controller had an accurate understanding of the developing traffic situation.

Once the confliction between the two aircraft developed, valuable time was wasted by both controllers discussing the situation, rather than resolving the problem. It was fortunate that the SMC controller had an awareness of the traffic situation and chose to intervene, thereby, prompting action to resolve the confliction before separation standards were infringed.

Summary

The pilot of a piper Archer was cleared for final by the Terminal Area (TMA) controller for a practice runway 35 Instrument Landing System (ILS) approach at Canberra. The duty runways at Canberra were 17 and 12. A Saab 340, VH-KDQ, had recently departed from Canberra using runway 17 when the Canberra surface movement controller (SMC) recognised that it was tracking in the opposite direction towards the Archer which was on final approach. The TMA controller took action to resolve the situation by instructing the pilot of the Archer to turn away from the ILS approach. The Archer was at about 8 NM on final approach at 4,500ft while KDQ was 2 NM upwind leaving 3,000ft on climb. The Canberra aerodrome controller (ADC) dept KDQ on frequency until he observed on radar that the Arhcer was turning and then instructed the crew of KDQ to contact the TMA controller.

The separation standard required between aircraft was either 3 NM laterally or 1,000ft vertically. Examination of recorded radar data indicated that the distance between the aircraft was about 4 NM laterally and 1,100ft vertically at the closest point of approach. There was no infringement of separation standards.

The TMA controller had moved the electronic flight strip for the Archer into the traffic management window of The Australian Advanced Air Traffic System (TAAATS) display, indicating that the aircraft was to carry out the ILS approach. The movement of the electronic strip into the traffic management window automatically indicated the pending arrival of the aircraft to the ADC in Canberra Tower. The ADC annotated the electronic strip with a "back-slash", which indicated an acknowledgment of the pending transfer.

Six aircraft had been issued airways clearances for departure from Canberra. The TMA controller was aware of the pending departures but he was not aware of when they would be ready for take-off. Two of those aircraft, Impulse 935 and VH-KJQ, subsequently taxied and the ADC advised the TMA controller that he was releasing those aircraft. Auto release procedures, which were in operation at the time, authorised the ADC to clear aircraft for take-off on pre-determined departure tracks after advising the TMA controller of the pending release. Auto release procedures were designed to minimise voice coordination between the TMA controller and ADC. Under auto release procedures, dependence was placed on the ADC to ensure that there was sufficient spacing between successive departing aircraft to enable the TMA controller to establish and maintain the required separation standard. The ADC advised the TMA controller that the Archer could "have the ILS" after those two aircraft, while also reiterating that there were a number of additional pending departures.

By the time KJQ had become airborne, a further three aircraft had taxied for departure: Eastern 832, Impulse 917 and KDQ. The ADC advised the TMA controller that two of the aircraft were approaching the holding point and one was just leaving the parking apron. The ADC also instructed the TMA controller to "hold [the Archer] out". The TMA controller did not acknowledge that instruction nor did the ADC seek acknowledgment. The ADC subsequently advised the TMA controller that he was releasing "Eastern 832 followed by Impulse 917 then KDQ". The TMA controller replied "Roger".

The TMA controller was required to annotate his electronic flight strip with an "A" for each aircraft to signify that auto-release coordination had been carried out. After receiving the coordination on the latter three aircraft, the TMA controller did not immediately annotate his electronic strips. Rather he advised the pilot of the Archer of a further delay and provided radar vectors for re-sequencing. When he did annotate the electronic strips with an "A", he only annotated Eastern 832 and Impulse 917. The controller stated later that he might have omitted to annotate the electronic strip for KDQ by confusing that aircraft with KJQ, the crew of which had just called the controller with a departure report.

The TMA controller then vectored the Archer to carry out the ILS approach after the departure of Impulse 917. After that crew had contacted the TMA controller, the pilot of the Archer was cleared for final for the ILS approach. By the time KDQ became airborne, a further two aircraft had taxied and the ADC coordinated their release with the TMA controller. The TMA controller queried that they would be "after" the Archer, to which the ADC replied "no they're RPT [Regular Public Transport] they've got higher priority they are going".

The ADC and TMA controllers then entered into a discussion about the situation that lasted about 26 seconds. During that period neither controller seemed to understand where the aircraft under the other person's control was in relation to the aircraft under their control. It was not until a third party, the Canberra SMC, intervened that the controllers understood there was a potential conflict situation and the TMA controller then took action to resolve the situation.

Auto-release procedures

Canberra Local Instructions stated that prior to issuing a take-off clearance, the ADC "shall advise the TMA controller of the pending release and receive an acknowledgment by callsign". During this occurrence, the ADC released five aircraft: none were acknowledged by callsign nor were callsign acknowledgments sought.

Voice coordination - arriving aircraft

Movement of the electronic flight strip into the traffic management window and acknowledgment of the sequence by annotating the strip with a backslash was normally the only coordination required between the TMA and the ADC for an arriving aircraft. Canberra Local Instructions stated that, in addition to the use of the traffic management strip, the TMA controller "shall voice coordinate when:

a) An instrument approach other than a straight-in approach to the system arrival runway will be conducted."

Further, Canberra Local Instructions stated that use of the reciprocal runway directions may be approved for individual aircraft:

"a) when an aircraft is conducting a practice instrument approach and missed approach subject to mutual agreement between TMA and CBA [ADC]".

From the time the Archer was turned away from the ILS approach on the first occasion there was no mutual agreement between the controllers for the use of the reciprocal runway and there was no voice coordination regarding the subsequent approach for the aircraft.

Traffic Management

The Archer pilot contacted the Melbourne Senior Terminal Area Controller (STAC) to book a training ILS approach at Canberra. The booking system established an order of priority for flight crews competing for training ILS approaches. It was reported that it would be unusual for the STAC to deny an ILS booking. It was mainly a paperwork exercise and there were no known busy times blocked out on the booking sheet. In this particular instance there was no coordination between the FMA staff and Canberra tower staff regarding the suitability of the timing of the training ILS approach for the Archer, despite seven pending departures from the reciprocal runway around the same time.

Organisational Issues

The Canberra TMA controllers were originally co-located with the aerodrome function in Canberra. During that time controllers were rotated through both TMA and aerodrome elements. In 1994, the TMA element was relocated to Melbourne. The controllers involved in this occurrence had 5.5 and 7 years experience respectively in their positions at Canberra Tower and in Melbourne. During that time, both had two familiarisation visits to each other's unit. In both cases, one visit was prior to the transition to TAAATS and one was as part of the transition process. Neither controller believed that the frequency of these visits was sufficient to maintain an appropriate level of awareness and appreciation of the other person's working environment.

Occurrence summary

Investigation number 200101080
Occurrence date 05/03/2001
Location 2 km S Canberra, Aero.
State Australian Capital Territory
Report release date 05/02/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Breakdown of co-ordination
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Piper Aircraft Corp
Model PA-28
Registration VH-MIZ
Serial number 28-7790276
Sector Piston
Operation type Flying Training
Departure point Canberra, ACT
Destination Canberra, ACT
Damage Nil

Aircraft details

Manufacturer Saab Aircraft Co.
Model 340
Registration VH-KDQ
Serial number 340B-325
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Canberra, ACT
Destination Sydney, NSW
Damage Nil