Amateur Built Aircraft Lancair 235, VH-LWA

Summary

The pilot of the Lancair had built the aircraft as an owner-builder. He and his passenger had intended to fly from Perth, Western Australia to an airshow at Mangalore, Victoria. On the day prior to the accident, the aircraft arrived early in the afternoon at Aldinga, South Australia, where it was refuelled in preparation for the next leg of the flight. The pilot and passenger then stayed overnight with a friend. The following morning, the aircraft departed for Murray Bridge, South Australia in order to meet up with another aircraft for the remaining flight to Mangalore.

When the aircraft was 3 km to the north-east of Aldinga aerodrome, witnesses heard the engine surge and lose power. The aircraft was then seen to enter a spin and crash into a dry creek bed. Both occupants were fatally injured. The accident was not considered to be survivable.

Traces of aviation fuel were found on the ground at the accident site under the wing fuel tanks. There was no evidence that a significant quantity of fuel had been released during the impact. There had been no post-impact fire.

The investigation established that the aircraft had been refuelled the previous day at Aldinga to a capacity of approximately 80L. It was operating within weight and balance limitations, close to its maximum weight, and close to the aft limit of its centre of gravity. There was no evidence to suggest that the aircraft was not airworthy prior to the accident, nor was there any indication that either the pilot or the passenger had been incapacitated immediately before the accident.

The aircraft utilised three fuel tanks: one was located in each wing below the level of the engine, while the third fuel tank was located in the fuselage, above the level of the engine. The engine could be fed with fuel directly from any one of these.

It was the pilot's normal policy to use fuel from the fuselage tank when priming the carburettor prior to starting the engine, and then to select a wing fuel tank once the engine had been started. During the flight from Western Australia, only the wing fuel tanks had been filled at all refuelling ports except for Ceduna, where it was not possible to ascertain how the aircraft had been refuelled. Investigation revealed that at the time of the accident, the low-fuel warning light for the fuselage tank was illuminated, indicating that only a small quantity of fuel remained in that tank.

The investigation found that aviation fuel had been spilled on the ground, chemically burning the grass, at the aircraft's overnight parking location at Aldinga aerodrome. The shape of the burnt grass area was consistent with fuel having been spilled over the sides of a 20 L fuel drum. Police reported that fuel had been stolen on other occasions from aircraft at Aldinga aerodrome. A road near the aerodrome was regularly used for car racing, and it is possible that fuel was siphoned overnight from the aircraft's fuel tanks.

Damage to the aircraft systems precluded a determination of the fuel tank that was selected at the time of the accident. A lack of both fire damage and evidence of fuel spillage at the accident site indicated that there was only a small quantity of fuel in the aircraft at the time of the accident, despite the aircraft having been refuelled the previous day. It was not possible to ascertain if the engine lost power due to fuel exhaustion from a wing fuel tank, or if the fuselage tank had been selected prior to take-off and that that tank had become exhausted.

The reason for the aircraft entering a spin after the engine lost power could not be determined.

Occurrence summary

Investigation number 199901340
Occurrence date 02/04/1999
Location 3 km NE Aldinga Aero.
State South Australia
Report release date 21/12/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Fuel exhaustion
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Amateur Built Aircraft
Model Lancair
Registration VH-LWA
Serial number W139
Sector Piston
Operation type Private
Departure point Aldinga, SA
Destination Murray Bridge, SA
Damage Destroyed

Piper PA-36-375, VH-HSQ

Safety Action

  1. The pilot did not ensure that the road was clear prior to commencing the take-off.
  2. The pilot did not observe a vehicle travelling along the road.

Summary

The pilot of a Piper Pawnee Brave had undertaken to spray an extensive area of land with a herbicide. He commenced operations at around daybreak, departing from his base with a load of chemicals. After that trip, and for the rest of the day, he operated from an airstrip on a property closer to the spray area.

The strip was a private access road that had been upgraded for a length of 800 m to serve as an airstrip. It ran perpendicular to a north-south sealed public road. Adjacent to the sealed road, and running parallel to it, was a powerline about 5 m high. The western end of the airstrip was about 50 m from the powerline. There were no signs on the road to warn motorists that low flying aircraft may be operating from the strip and crossing the road at low level. On each flight the pilot was landing the aircraft towards the east and taking off towards the west.

Because of its weight, the aircraft was flown under the powerline during most take-offs. Prior to commencing each take-off, the pilot checked for traffic on the road. From the cockpit he had a view of the road for about one kilometre in each direction. The pilot commented that he had to wait for traffic on a number of occasions during the day. He reported that because of fatigue and the low sun angle during the accident flight, he did not notice a vehicle travelling south. Just after becoming airborne the pilot saw the car but was unable to take avoiding action.

The left main wheel of the aircraft collided with the front left corner of the car's cabin and ran across its roof before breaking off and coming to rest in an adjacent paddock. The pilot considered that the aircraft was operating normally so he continued with the intended spraying operation and then returned to his home base for a landing. He provided no explanation as to why he did not report the accident immediately.

The driver of the car stated that she saw the aircraft just prior to the impact but was unable to take avoiding action. A passenger in the front seat received lacerations from the broken windscreen.

Occurrence summary

Investigation number 199901299
Occurrence date 28/03/1999
Location 28 km W Pittsworth
State Queensland
Report release date 19/01/2000
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 Serious

Aircraft details

Manufacturer Piper Aircraft Corp
Model PA-36
Registration VH-HSQ
Serial number 36-8202019
Sector Piston
Operation type Aerial Work
Departure point 28 km W Pittsworth, QLD
Destination 28 km W Pittsworth, QLD
Damage Substantial

Boeing 767-238, VH-EAN

Safety Action

As a result of the fan blade fracture, the engine manufacturer and operator took safety action to address shroud lockup, leading edge erosion and blade foreign object damage.

Shroud lubrication

  1. The manufacturer issued service information on fan blade shroud lubrication and recommended that lubrication of the fan blade shroud hardface surfaces be performed at every "A" check. The manufacturer revised the JT9D-7R4 Engine Maintenance Manuals to incorporate the lubrication procedure. No on-wing shroud lubrication had previously been required.
  2. The operator incorporated the fan blade shroud lubrication procedure into their Maintenance Manual. Lubrication of the fan blade shrouds is to be carried out after a compressor wash, both on-wing and in the test cell, and during workshop assembly.

Fan blade leading edge erosion

  1. The manufacturer recommended that the operator maintain proper leading edge contours on all fan blades as per the Engine Manual, and that leading edge restoration be performed between 2,000-3,000 cycles, with a 5,000 cycle maximum time between refurbishment.
  2. The operator commenced a program to recontour the fan blade leading edges as per the Engine Manual every 2,500 cycles. Procedures were put in place to monitor and track the time and removal of fan blade sets reaching the 2,500 cycle threshold. A set of float fan blades and tooling was ordered to support the program.

Foreign object damage inspection

  1. The manufacturer recommended that the operator inspect fan blades for foreign object damage in accordance with the maintenance manual.
  2. The operator advised that a routine visual inspection for foreign object damage as per the maintenance manual was already in place and was conducted every 200 cycles. An eddy current inspection of the fan blade leading edge is performed every 350 airframe hours.
  3. Immediately following the fan blade failure, the operator conducted a close visual and eddy current inspection of all Boeing 767 engine fan blades. A number of damaged fan blades were found and corrective action taken.

Analysis

The fractured fan blade and several liberated portions of the blade were examined by the ATSB and by the engine manufacturer. The other 39 fan blades were returned to the engine manufacturer for review.

The blade had fractured about 470 mm above the blade platform, just inboard of the mid-span shroud. About one-quarter of the blade had been liberated. The fan blade had fractured as a result of fatigue crack growth. The failure had originated at a foreign object damage impact site 2.54 mm aft of the blade leading edge on the rear (concave) face of the blade. Traces of mineral debris were detected at the crack origin, indicating that the foreign object damage was the result of stone ingestion. Fatigue crack growth, from a crack depth of 1.5 mm, probably occurred over about 35 flight cycles. The blade had no material abnormalities at the fracture site. No evidence of a birdstrike was found.

The fractured blade had an eroded leading edge in the mid-span shroud region of the fan blade. The engine manufacturer reported that all of the fan blades had eroded leading edges in front of the mid-span shroud (about 152 mm above and below the shroud), and that the shroud hardfaces showed signs of possible lockup. It could not be determined whether the shroud lockup had occurred before or after the fan blade fracture.

The cracking and fracture of the fan blade appeared to be the result of high stress at a foreign object damage impact location in combination with vibratory stress and possible locked shrouds. The manufacturer reported that an adverse combination of these items could produce stresses high enough to fracture a fan blade. The eroded leading edge evident on all fan blades would have contributed to the blade fracture by affecting the vibratory characteristics of the fan blades.

The engine manufacturer said there had been only one other reported fracture of this type of fan blade. This was also due to fatigue crack growth starting at a foreign object damage impact site at a similar radial location to this fracture.

Findings

  1. A fan blade of the right engine fractured as a result of fatigue crack growth during aircraft climb, resulting in shutdown of the engine.
  2. The crack originated at a foreign object damage impact site on the rear face of the blade near the mid-span shroud.
  3. All fan blades of the right engine had significant leading edge erosion/blunting in the mid-span shroud region.
  4. The fan blade shroud hardfaces showed signs of shroud lockup.
  5. High stress at the foreign object damage impact site, vibratory stresses due to blade leading edge erosion and possible locked shrouds caused the crack to grow.
  6. Liberation of one-quarter of the fan blade and the resulting fan imbalance damaged the fan case, nose cowl and other fan blades.

Factual Information

History of the flight

Approximately 21 minutes after departure while the Boeing 767 was passing through flight level (FL) 285 on climb to FL310, a loud bang sound was heard from the right engine. Cabin crew and passengers reported a flash and sparks from the rear of the engine. The pilot reported an immediate drop in the right engine pressure ratio (EPR) and a rise in the exhaust gas temperature (EGT). A moderate vibration was felt through the airframe.

The crew actioned the engine surge/stall checklist but as the EGT continued to increase, the engine severe damage/separation checklist was actioned and the right engine was shut down. The engine fire bottles were not discharged.

The crew made a PAN call stating that the right engine had failed and requested a descent to FL240 and a return to Sydney. The pilot reduced speed to 240 kts in an attempt to reduce the vibration. However, the vibration reduced only during the final approach.

Engine inspection

An inspection of the right engine revealed that about one-quarter of the no. 28 fan blade had broken away, resulting in substantial damage to the inside of the nose cowl and to the majority of the fan blades. Abnormal displacement of fan blades (shingling) was evident on the mid-span shrouds of a number of blades surrounding the fractured blade.

The fan blade attrition lining was damaged around its entire circumference as a result of heavy fan blade rub. The forward fan case was distorted with five nose cowl attachment points damaged.

The nose cowl internal acoustic liners were damaged through to the outer skin in several locations with two punctures of the nose cowl outer skin. The nose cowl had shifted forward, creating a gap between the nose cowl and the forward fan case flange. Fan blade debris and the mid-span shroud root section of the fractured blade were found embedded in the nose cowl following removal of cowl access panels.

Fan blade maintenance

Operator maintenance records indicated that the right engine fan blades were inspected for leading edge cracks on 13 March 1999 (93 hours and 54 cycles prior to the incident). No indications of cracks were detected at that time. Routine inspections of the fan blade leading edges for cracks had been carried out on a monthly basis. A vibration survey test was carried out on 2 February 1999 after removal and inspection of two fan blades.

In the 9 months before the incident, 13 fan blades on the right engine were found to have incurred foreign object damage. These blades had been blend repaired and inspected for cracks. The fractured fan blade was not one of those blades.

The operator reported that fan blade leading edge restoration was carried out at a 5,000 cycle interval or at 3,000 cycles should an overhaul opportunity occur. Lubrication of the mid-span shroud to help prevent shroud lockup was not required while the engine was fitted to an aircraft (on-wing). The fan blades were overhauled 6,689 hours / 3,889 cycles before this incident.

Occurrence summary

Investigation number 199901215
Occurrence date 22/03/1999
Location 56 km E Cowra, (NDB)
State New South Wales
Report release date 22/11/2000
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 The Boeing Company
Model 767
Registration VH-EAN
Serial number 23402
Sector Jet
Operation type Air Transport High Capacity
Departure point Sydney, NSW
Destination Perth, WA
Damage Minor

Boeing 747-200, DQ-FJI

Factual Information

Following flap retraction shortly after the Boeing 747 departed Sydney, the crew reported a flap disagreement indication. The flaps could not be extended and were stuck in the up position. The aircraft returned to Sydney where the crew carried out a flapless landing.

An inspection revealed that the right inboard fore-flap carriage stop had failed. This resulted in extensive damage to the fore flap, mid flap, and overload failure of the right flap drive torque tubes.

Specialist examination found that the fore-flap carriage stop failed due to stress corrosion cracking. The cracking initiated at the bolt hole surface. The manufacturer's instructions require that the bolt should be installed with wet sealant, however inspection indicated that the sealant did not cover the centre portion of the bolt, potentially allowing moisture to enter.

Occurrence summary

Investigation number 199901111
Occurrence date 16/03/1999
Location Sydney, Aero.
State New South Wales
Report release date 02/01/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Flight control systems
Occurrence class Accident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration DQ-FJI
Serial number 22145
Sector Jet
Operation type Air Transport High Capacity
Departure point Sydney, NSW
Destination Nadi, FIJI
Damage Substantial

Boeing 737-377, VH-CZL

Factual Information

History of the flight

At the appropriate time during the approach sequence, the co-pilot of the Boeing 737, who was the handling pilot for the sector, called for the landing gear to be extended. When the pilot in command placed the landing gear lever to the "down" position, a loud thump was heard and the "gear safe" green light for the right main gear illuminated immediately. This was followed by the illumination of the left main and nose landing gear lights, consistent with a normal extension sequence. The aircraft rolled approximately 4 degrees to the right while the gear was extending. This was counteracted by a left roll control input.

As the crew had received indications that the landing gear was safely locked down, they continued the approach and completed a normal landing.

Ramp maintenance staff briefly inspected the aircraft but did not find any immediate cause for the reported thump. The aircraft was then placed on jacks for a retraction test. When the landing gear lever was selected to the "up" position, the right main landing gear moved inboard approximately 15 cm before a grinding noise was heard. The test was immediately suspended and the landing gear was extended.

When access panels were removed, it was found that the actuator beam arm inboard lugs and beam hanger had fractured. The rear wing spar, landing gear beam, aileron bus cable, pulley bracket, aileron and spoiler cables and hydraulic lines had been damaged extensively following the fracture of the lugs and hanger.

Actuator beam arm examination

Inspection of the actuator beam arm revealed that the fracture of both lugs was due to stress corrosion cracking.

Service information

The manufacturer addressed main landing gear (MLG) corrosion and cracking problems with the issue of Service Bulletin (SB) 737-32A1224 in July 1989 and with production changes to the beam arm assembly. Revision 2 of this SB was issued in April 1991 and Part A of this SB was mandated by the issue of Federal Aviation Administration (FAA) Airworthiness Directive (AD) 91-05-16, and by the issue of Australian Civil Aviation Safety Authority AD/B737/57. The AD action required in-situ inspection of the beam arm at 600 flight-cycle intervals. Alternatively, modification or replacement of the beam arm with a new production arm could be accomplished as a terminating action.

The modified beam arm assemblies incorporated the following changes to improve the corrosion resistance of the actuator beam arm and actuator beam attach bolt:

- improved bushings,
- an increased bushing interference fit,
- an improved actuator beam bolt,
- more extensive cadmium plating, and
- improved lubrication of components.
 

SB 737-32A1224 Rev 3, issued in October 1992, recommended replacing the actuator beam arm components with production components rather than part modification.

There have been two reports of lug failures on beam arm assemblies that had been modified by AD 91-05-16. These failures occurred overseas in March 1997 and October 1998 and were similar in nature to this incident.

Maintenance history

The operator advised that in July 1991, the right beam arm fitted to the aircraft involved in the March 1999 incident was reworked for incorporation of SB 737-32A1224 Rev 2 at the operator's maintenance facility. In June 1993, the right MLG was overhauled at an overseas maintenance facility. In June 1993, the beam arm was installed with the MLG onto the aircraft. At the time of failure, the beam arm had been in service for 33,681 flight hours, 25,025 flight cycles and 10.25 years. The period since last overhaul was 17,879 flight hours, 12,296 flight cycles and 5.75 years.

ANALYSIS

When the aircraft was on the line it showed no visible damage, however, the operator elected to carry out a more comprehensive inspection. Fracture of the lugs causes the main landing gear to fall back to the extended position and is therefore fail-safe in that respect. However, an actuator beam arm fracture allows the actuator, actuator beam, and support link to travel outboard, contacting and possibly damaging the main landing gear beam and the wing rear spar. It can also result in contact with nearby flight control cables (aileron and spoiler) and hydraulic lines. This contact has the potential of inadvertent flight control inputs that could reduce the controllability of the aircraft.

The aileron bus cable in this incident was found to be almost completely severed. This damage potentially could have resulted in serious control problems.

The aircraft right roll experienced during gear extension was considered to have been the result of the right landing gear extending more rapidly than the left landing gear, and not as a result of flight control inputs caused by the actuator beam arm failure.

The location of the fractures in both inboard lugs of the right actuator beam arm coincided with the positions for possible cracks identified in SB 737-32A1224. The fractures in the lugs were a result of stress corrosion cracking. Previous failures analysed by the manufacturer were also attributed to stress corrosion cracking.

Stress corrosion cracking of high-strength steel components of aircraft main landing gears occurs when the components are subjected to a sustained tensile stress and are exposed to an environment that allows stress corrosion cracking to initiate. The components are susceptible to stress corrosion cracking when exposed to the normal operating environment of landing gear (moisture, salt laden moisture). Stress corrosion cracking in the actuator beam arm lugs occurred as a result of the movement of the bushes installed in the lugs and the penetration of moisture into the gap created between the bushes and lugs.

The ATSB Technical Analysis Report 19/01 further analysed failures of B737 main landing gear pin/lug joints and is available on the ATSB website or on request from the ATSB.

SAFETY ACTION

Operator fleet inspection

As a result of this incident, the operator conducted visual and ultrasonic inspections of the actuator beam arms of its fleet of Boeing 737 aircraft. A cracked actuator beam arm was found during inspection of another aircraft.

As a result of this occurrence, the ATSB (which includes the former Bureau of Air Safety Investigation) issued interim recommendations (IRs) to the manufacturer, regulators and operators on 19 March 1999 and identified the following safety deficiency:

"Damage to flight control cables and primary aircraft structure resulting from the failure of main landing gear (MLG) actuator beam arm lugs of B737 aircraft has the potential to seriously affect the safety of flight."

IR19990019

The Bureau of Air Safety Investigation recommends that Boeing Commercial Airplane Group alert Boeing 737 operators to this safety deficiency and implement an appropriate inspection program.

The following response (in part) was received from the Boeing Commercial Airplane Group on 6 April 1999:

"We have released Boeing All- Operator Message M-7200-99-02383 dated 26 March 1999. In summary we plan to release an alert service bulletin (737-32A1314) by the end of April, 1999. This bulletin will call for the resumption of the ultrasonic inspections of all Main Landing Gear Beam Arms every 600 flight cycles upon the accumulation of 10,000 cycles or 4 years (whichever comes first). This will be considered interim action until we have analyzed and implemented the course of terminating action to preclude the onset of corrosion noted in the parts."

Boeing released alert service bulletin 737-32A1314 on 15 April 1999 requiring all 737-100, -200, -300, -400, -500 airplane operators to do a visual and ultrasonic inspection of the clevis on the actuator beam arm. If cracks or corrosion are found, the actuator beam arm is to be replaced. Boeing recommended this inspection be done before the actuator beam arm has 10,000 cycles or four years of service. Boeing recommended the inspection be repeated every 600 flight cycles or 90 days (whichever occurs first).

Boeing advised that they were evaluating design improvements that will further inhibit the initiation of corrosion of these high strength steel parts. Boeing expected to complete the evaluation and begin implementation of the new hardware by the fourth quarter of 2002.

Response classification: CLOSED-ACCEPTED.

IR19990020

The Bureau of Air Safety Investigation recommends that Boeing Commercial Airplane Group review the effectiveness of Service Bulletin 737-32A1224.

The following response (in part) was received from the Boeing Commercial Airplane Group on 6 April 1999:

"Prior to the original release of the bulletin in 1989, operators were reporting medium - to - heavy corrosion of the beam arms (in addition to several reports of fractures). Following the second post - bulletin fracture report (dated 6 October 98 in the table above), we conducted a survey of operators and asked for an assessment of the condition of beam arms in service. In general, most operators who responded (representing just over 1300 airplanes) reported very little (if any) corrosion. The basic response is that, although the bulletin appears to have been effective in reducing the reported corrosion, it has not eliminated the potential for corrosion that leads to the possibility of cracking of the beam arm lugs. Therefore, we are undertaking the actions as noted in the response to recommendation IR990019 above."

Response classification: CLOSED-ACCEPTED.

IR19990021

The Bureau of Air Safety Investigation recommends that the Federal Aviation Administration note the above safety deficiency and interim recommendations and take appropriate action as considered necessary to ensure the integrity of Boeing 737 main landing gear actuator beam arm assemblies.

The following response was received from the US Federal Aviation Administration on 24 May 1999:

"The US Federal Aviation Administration issued an Airworthiness Directive (AD 99-10-12) as Amendment 39-11165 to all B737 operators, effective 27 May 99:

SUMMARY: This amendment supersedes all existing airworthiness directive (AD), applicable to certain Boeing Model 737-100, -200, -300, -400, and -500 series airplanes, that currently requires repetitive inspections to detect cracking, plating degradation, and corrosion of the main landing gear (MLG) actuator beam arms and actuator beam attach bolts; and rework or replacement, if necessary. The existing AD also provides for optional terminating action for the repetitive inspections. This amendment removes the requirement to inspect the actuator beam attach bolts, expands the applicability of the existing AD to include additional airplanes, and removes the optional terminating action. This amendment is prompted by reports of cracked MLG actuator beam arms. The actions specified in this AD are intended to detect and correct corrosion and cracking of the MLG actuator beam arm, which could result in damage to the control cables for the aileron and spoiler and consequent reduced controllability of the airplane."

Response classification: CLOSED-ACCEPTED.

IR19990022

The Bureau of Air Safety Investigation recommends that the Civil Aviation Safety Authority initiate appropriate action to ensure that Australian operators of Boeing 737 aircraft immediately inspect all main landing gear actuator beam arm assemblies for evidence of cracking.

The following response was received from the Civil Aviation Safety Authority on 08 June 1999:

"I refer to your interim recommendation IR990022 in regard to the Actuator Beam Arm failure on B737 VH-CZL on 12th Mar 1999. The incident resulted in substantial secondary damage to the wing structure and flight control cables, and it was this damage, rather than the undercarriage failure, which was of major concern (the undercarriage is designed to fail safe).

CASA has investigated the incident, and found that this failure was previously covered by inspections mandated by AD/B737/57. Those inspections ceased after a modified actuator beam arm was installed, as nominated by the AD as closing action. VH-CZL had a modified actuator arm beam, and inspections for cracking were therefore not required.

The significance of the secondary damage suffered by VH-CZL was such that CASA decided to reintroduce initial and repetitive inspections by reissue of AD/B737/57 Amendment 1. This amended AD was issued on 29 March 1999 and requires visual and ultrasonic inspections even if the actuator arm had been replaced. Boeing was advised of the action and requested to advise us when suitable terminating action is developed.

The US FAA was also advised of our action. The FAA has subsequently issued AD 99-10-12 effective 27 May 99 to perform almost identical work as required by the CASA AD. The FAA AD was issued as a final form without industry consultation.

The action initiated is considered adequate to correct the unsafe condition revealed by the incident involving VH-CZL. This action will be reviewed when further information is received from Boeing or the FAA.

Receipt of IR990022 enabled urgent corrective action to be initiated by CASA, and subsequently by Boeing and the FAA. Expeditious issue of IR990022 by BASI is therefore much appreciated."

Response classification: CLOSED-ACCEPTED.

IR19990023

The Bureau of Air Safety Investigation recommends that Australian operators of Boeing 737 note the above safety deficiency and interim recommendations and take appropriate action as considered necessary to ensure the integrity of Boeing 737 main landing gear actuator beam arm assemblies.

The following response was received from Ansett Australia on 8 April 1999:

"As you are aware the company conducted initial visual checks and then NDT inspections of the affected area of the B737 landing gear. All the inspections were completed some weeks ago. We found another failed part in VH-CZU and those components have been sent to BASI for analysis.

The company has received no further information from the manufacturer at this time."

The following response was received from Qantas Airways Limited on 12 April 1999:

"Qantas was notified by Ansett of the VH-CZL occurrence through Safety and Engineering Departments contacts. Qantas Engineering conducted initial visual inspections on the entire B737 fleet on 12 and 13 March 1999.

In addition, an instruction was issued to carry out both ultrasonic inspection in accordance with SB 737-32A1224 Revision 2, and also a bush rotation check, which is to check for bolt binding within the bush, causing bush movement.

The initial inspections targeted beam arms with greater than 10,000 hours and no defects were discovered by the end of March 1999. All Qantas units are post SB737-32A1224 status and have either been modified in-house or are Boeing as-new replacements."

Response classification: CLOSED-ACCEPTED.

Summary

At the appropriate time during the approach sequence, the co-pilot of the Boeing 737, who was the handling pilot for the sector, called for the landing gear to be extended. When the pilot in command placed the landing gear lever to the "down" position, a loud thump was heard and the "gear safe" green light for the right main gear illuminated immediately. This was followed by the illumination of the left main and nose landing gear lights, consistent with a normal extension sequence. The aircraft rolled approximately 4 degrees to the right while the gear was extending. This was counteracted by a left roll control input.

Occurrence summary

Investigation number 199901073
Occurrence date 12/03/1999
Location Melbourne, Aero.
State Victoria
Report release date 08/10/2001
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-CZL
Serial number 23664
Sector Jet
Operation type Air Transport High Capacity
Departure point Launceston, TAS
Destination Melbourne, VIC
Damage Substantial

Saab SF-340B, VH-KDQ

Summary

A Saab SF-340B (Saab) was conducting a scheduled passenger service from Canberra to Sydney and had been assigned descent to 7,000 ft by the Approach South radar controller in order to maintain the minimum vertical separation standard of 1,000 ft, between the Saab and a Piper Chieftain. The Chieftain was ahead in the approach sequence and had been assigned descent to 6,000 ft. The two aircraft were separated laterally by distances greater than the minimum radar separation standard of 3 NM, but their respective tracks were converging.

The controller requested the Saab crew to expedite descent to 7,000 ft. That instruction was read back by the pilot in command, however, the readback was indistinct. The controller repeated the request "Expedite descent to 7,000 ft". The pilot in command acknowledged that transmission with the aircraft's callsign. Shortly after, the controller observed that the altitude readout for the Saab was indicating that the aircraft was descending through 7,000 ft. The controller queried the Saab crew to confirm that they were maintaining 7,000 ft, then instructed the crew to turn left onto a heading of 360 degrees due to the traffic ahead. As the crew responded to that instruction, the lateral and vertical separation between the Saab and the Chieftain reduced to 1.5 NM and 500 ft respectively.

The traffic sequence had been busy, with the controller endeavouring to change the landing sequence by placing the Saab ahead of the Chieftain. The controller was required to monitor the lateral and vertical separation between a number of aircraft as two standard arrival routes converged. As a consequence, the controller was required to establish vertical separation to ensure separation was maintained between all aircraft as they approached an area of lateral conflict.

All radio transmissions between the controller and the Saab were recorded. A review of the recorded information indicated that the altitudes assigned by the controller, and the readbacks from the Saab crew, were clear and distinct except for the response to the controller's initial request to expedite descent. The Saab crew were unable to explain why they were not alerted to the possibility of an incorrect altitude following the controller's reiteration of the request to expedite descent to 7,000 ft.

The Aeronautical Information Publication GEN 3.4-10 paragraph 4.4 details readback requirements for flight crew. For other than a route clearance, "the key elements of clearances, instructions or information must be read back ensuring sufficient detail is included to clearly indicate compliance". A level instruction must be read back. In this occurrence, the controller did not expect a readback of the altitude, because the previously assigned altitude had not changed. The indistinct response from the Saab crew caused the controller to doubt that his request had been understood, so he repeated the request. When that transmission was acknowledged by the pilot in command, the controller believed that the crew now understood his request to expedite descent to 7,000 ft.

The Saab crew believed that an altitude clearance of 6,000 ft had been issued between the time the controller assigned them 7,000 ft, and when the controller requested that they expedite descent to 7,000 ft. However, the recorded transmissions did not include any reference to 6,000 ft directed to, or received from, the Saab crew during that period.

Occurrence summary

Investigation number 199901070
Occurrence date 17/03/1999
Location 28 km WSW Sydney, (VOR)
State New South Wales
Report release date 27/04/1999
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 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

Aircraft details

Manufacturer Piper Aircraft Corp
Model PA-31
Registration VH-JVD
Serial number 31-7852041
Sector Piston
Operation type Air Transport Low Capacity
Departure point Shepparton, VIC
Destination Sydney, NSW
Damage Nil

Airbus A320-211, VH-HYJ

Safety Action

The Bureau of Air Safety Investigation is currently investigating the underlying factors associated with number 4 bearing failures in CFM-56 engines.

Any recommendation issued as a result of this investigation will be published in the Bureau's Quarterly Safety Deficiency Report.

Summary

While cruising at flight level 390 (FL390) the number 1 engine failed. The crew made a PAN call to air traffic control (ATC) advising of the problem and requesting descent. A descent clearance was issued and the aircraft was given a direct track for final approach to runway 34L. An alert phase was declared by ATC. The pilot subsequently advised that no emergency existed and that a normal approach and landing was expected. As a precaution, emergency services were placed on a local standby. The aircraft subsequently landed safely.

An inspection of the engine by the operator found that both the high and low-pressure rotating assemblies were seized, and that there was light metal contamination on the chip detector. After removing and dismantling the engine, it was determined that the number 4 bearing had failed. The operator reported that the bearing had been in service for 21,004 hours since new, and 10,128 hours since the last visual inspection of that component. The chip detector had been inspected about 25 hours prior to the failure and found clean.

There have been two other similar reported failures in Australia. The engine manufacturer has reported that an improved bearing will be available shortly. The operator plans to review chip detector inspection periods in the interim.

Occurrence summary

Investigation number 199901098
Occurrence date 18/03/1999
Location 150 km SW Sydney, Aero.
State New South Wales
Report release date 08/09/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Airbus
Model A320
Registration VH-HYJ
Serial number 142
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination Sydney, NSW
Damage Nil

Fairchild SA226-TC, VH-EEQ

Safety Action

As a result of this investigation the following interim recommendations were issued.

IR19990112

The Bureau of Air Safety Investigation recommends that the engine manufacturer, AlliedSignal, audit the process employed to manufacture TPE 331 turbine wheel knife-edged seals should be audited to determine those factors that may lead to excessive variations in slot corner radii.

IR19990113

The Bureau of Air Safety Investigation recommends that the engine manufacturer, AlliedSignal, determine the sensitivity of turbine wheel seals to the initiation of fatigue cracks from slot corners, as a function of slot corner radii.

IR19990114

The Bureau of Air Safety Investigation recommends that the engine manufacturer, AlliedSignal, consider, during engine design and the formulation of continuing airworthiness instructions, the possibility that turbine wheel seal fatigue failure may result in hazardous modes of engine failure.

IR19990115

The Bureau of Air Safety Investigation recommends that the Civil Aviation Safety Authority Australia conduct an audit of that part of the aviation safety system that establishes the operational history of life-limited components, to establish why the operational history of second-stage turbine wheel, p/n 868272-1, s/n P03214C, could not be determined with certainty.

IR19990116

The US Federal Aviation Administration should note the safety deficiency identified in this document and take appropriate action as considered necessary.

Analysis

The uncontained failure of the second-stage turbine wheel was caused by the progressive reduction of the wheel cross-section, during operation, near the transition from the hub to web. No material anomalies or regions of pre-existing crack growth were associated with the separation of wheel segments.

Analysis of the recovered turbine components revealed that the reduction in wheel cross-section was caused by the effects of sliding contact with sections of the fractured second-stage wheel knife-edged seal. The web was reduced from original approximately 13 mm to approximately 8.5 mm.

Examination of the remnants of the second-stage seal indicated that the fracture of the seal had occurred as a result of fatigue crack growth from the radii at the corners of the slots formed in the forward edge of the seal.

A significant variation in the radii of the slot corners was noted when a comparison was made between the fractured seal and the seal from another second-stage wheel assembly. The one intact slot corner of the fractured second-stage wheel seal was sharper and did not display the smoothly rounded characteristic of the corners of other seals. A decrease in radius would create an increase in stress concentration and increase the likelihood of fatigue crack initiation.

Summary

The right engine of a Fairchild Metro II aircraft, VH-EEQ, failed at the top of descent to Launceston. The aircraft subsequently completed an uneventful single-engine landing. On-site inspection revealed that the engine failure was caused by the disintegration of the second-stage turbine wheel and that segments of the wheel had penetrated the engine nacelle. One fragment penetrated the fuselage and was found lodged in the cabin lining.

The AlliedSignal TPE331-3U-304G engine, serial number P03214C, was reported to have completed 6,017.4 hours and 6,273 cycles since new.

The second-stage wheel was identified as part number 868272-1, serial number 1-01345-1313. The recorded history of the second stage wheel indicated that the wheel had been in service for a total of 2,972.84 hours and 2,878 cycles at the time of failure on 5 March 1999. The wheel was installed new in engine s/n P90105 on 11 Jan. 1982. It was removed from engine s/n P90105 on 25 Sept. 1992 with a recorded service life of 564.74 hours and 508 cycles. The wheel was installed in engine s/n P03214C on 30 Aug. 1994 with a recorded history of 564.74 hours and 508 cycles in service. There remain, however, uncertainties in the recorded service history of the part.

Occurrence summary

Investigation number 199901064
Occurrence date 05/03/1999
Location 54 km NNW Launceston, (VOR)
State Tasmania
Report release date 03/09/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Fairchild Industries Inc
Model SA226
Registration VH-EEQ
Serial number TC-251
Sector Turboprop
Operation type Charter
Departure point Melbourne, VIC
Destination Launceston, TAS
Damage Minor

Bell 47J-2A, VH-THH

Summary

A Bell 47J helicopter was being ferried by two pilots from Lyndock SA to Kings Creek Station NT over a period of 3 days. Refuelling stops were planned for Port Augusta, Roxby Downs, Coober Pedy, Cadney Park if required, and Kulgera. Additional equipment was also carried, including a ground refuelling hose and pump unit, aircraft manuals, hand tools, additional engine oil, water, and seven 20 L jerry cans of fuel.

The flight was uneventful to Cooper Pedy where a flight plan was lodged nominating Cadney Park and Kulgera as landing points. The helicopter subsequently departed at about 0730. When it failed to arrive at Cadney Park or Kulgera, a search was initiated. The burnt-out wreckage of the helicopter was located 2 days later in flat, open, sparsely timbered country, about 1 NM south-west of Temptation Bore and approximately 152 NM from Coober Pedy, close to the direct track to Kulgera. The accident was not survivable.

At the time of the accident the weather was fine and clear, with a light breeze from the south-east, and a temperature in the vicinity of 30 degrees Celsius.

Examination of the wreckage did not reveal any pre-existing defects which may have contributed to the accident. An intense post-impact fire fuelled by the fuel from the jerry cans had consumed the cockpit and forward section of the tail boom. The engine displayed severe impact and external fire damage, but all internal components were intact, well lubricated, and capable of normal operation. The fire had destroyed the fixed emergency locator transmitter mounted on a bracket at the forward section of the tail boom. The remains of a hand-held emergency locator beacon were found in the debris of the burnt cockpit. The damage sustained by the main and tail rotor assemblies was consistent with the transmission system not being powered at the time of impact. The rotational velocity of the main and tail rotor assemblies was very low at impact and it was likely that the main rotor RPM was too low for a controlled descent. Damage sustained by the engine cooling fan indicated it was not rotating at impact. Some of the flight control systems had been consumed by the fire, but the remainder were correctly connected and functioned normally. The pilot's collective lever and cyclic control stick had separated during the impact. Both displayed bending overload failures but no fire damage was evident.

One main fuel tank had collided with a main rotor blade during the impact sequence. That tank was ruptured and deformed from collision with the blade, and contained a minute quantity of fuel, but displayed no evidence of fire damage. The other main fuel tank was ruptured and heavily sooted externally, but contained no fuel, and there was no evidence of fire internally. The remainder of the fuel system was too extensively damaged to determine if a fuel leak had existed during flight. Of the seven jerry cans, most were ruptured and heavily sooted externally. Fire and explosives experts' analyses determined that the main tanks contained only a small quantity of unusable fuel at impact. The intensity of the fire indicated that there was a substantial quantity of fuel in the jerry cans. Earth displaced from the impact craters made by the forward cockpit section and tailskid was consistent with the helicopter being in a nose-down attitude, with some forward velocity at impact.

Maintenance records for the helicopter indicated that it had been correctly maintained in accordance with an approved system of maintenance. The maintenance release was current, and there were no outstanding maintenance requirements.

Both pilots were appropriately licensed for the flight. The pilot flying at the time of the accident had about 350 hours of rotary wing flight time, but had limited experience on the Bell 47J type. The pilot in the rear seat had over 7,000 hours rotary wing flight time, but his logbook indicated that he had not operated the Bell 47 type since before September 1997.

The estimated weight and balance of the helicopter on departure from Coober Pedy indicated that the centre of gravity was within approved limits and its weight was within the authorised maximum take-off weight.

The investigation determined that the main fuel tanks of the helicopter and the seven additional 20 L jerry cans were full when it departed Lyndock. The fuel management between Lyndock and the final refuelling at Coober Pedy could not be determined. After refuelling at Coober Pedy on the evening before the accident flight, the helicopter was hover taxied to another area for overnight parking. The main tanks were therefore less than full at departure from Coober Pedy the next morning. The range of the helicopter with full main tanks was insufficient to reach Kulgera and it would have had to land en route to be refuelled from the jerry cans in order to reach its destination.

It was reported that the pilot in the rear seat had flown the route several times and was known to refuel at locations of high visibility. He had refuelled at Aston Hill, about 15 NM north-north-west of Cadney Park on previous occasions but there was no evidence to suggest that the helicopter had landed between Coober Pedy and the accident site on this occasion.

Calculations using the known fuel quantities purchased at the previous enroute refuelling stops, indicated that the range of the helicopter with full main tanks should have been sufficient to reach Temptation Bore. The pilot may have been planning to land and refuel at Temptation Bore, which would have been visible in the near distance when the engine stopped from fuel exhaustion. The reason the engine stopped from fuel exhaustion and why the helicopter then collided heavily with the ground in a nose low attitude, with the rotor system rotating well below the speed required for a controlled descent, could not be determined.

Occurrence summary

Investigation number 199901057
Occurrence date 07/03/1999
Location 282 km NNW Coober Pedy, Aero.
State Northern Territory
Report release date 17/03/2000
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Fuel exhaustion
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Bell Helicopter Co
Model 47
Registration VH-THH
Serial number 3711
Sector Helicopter
Operation type Aerial Work
Departure point Coober Pedy , SA
Destination Kulgera, NT
Damage Destroyed

Short Bros Pty Ltd SD360-300 , SH3728

Safety Action

Local safety action

As a result of the investigation, Airservices Australia has:

  1. Introduced a revised missed approach procedure on 17 June 1999. This procedure changed the outbound heading from 030 degrees to 015 degrees, and
  2. Introduced Cairns Local Instruction TLI99/105 which restricted the available headings for departures to 030 degrees only, when missed approaches are likely.

The combined effect of these actions was to provide a nominal 15 degree buffer between the departure and missed approach paths.

Airservices Australia management at Cairns has introduced a program of regular in-flight emergency response and abnormal situation refresher training for tower staff. The first course was completed between 19 - 23 July 1999.

Recommendation

As a result of the investigation the Australian Transport Safety Bureau (formerly Bureau of Air Safety Investigation) issued the following recommendation to Airservices Australia on 23 December 1999:

R19990227

That Airservices Australia review ongoing refresher training for all staff. In particular, to ensure that adequate discussion and simulation of unusual situations pertinent to specific locations is included in the syllabus.

Airservices Australia responded on 7 February 2000 accepting the recommendation.

The Australian Transport Safety Bureau classified the response as CLOSED - ACCEPTED

Significant Factors

  1. The geographical restraints of high terrain surrounding the Cairns aerodrome required all aircraft movements in instrument meteorological conditions to proceed into a 40 degree sector of airspace.
  2. The Cairns runway 15 missed approach and departure procedures required all aircraft to turn into the same narrow sector of airspace.
  3. The weather conditions were such that missed approaches were likely and that the aerodrome controller would not be able to provide visual separation.
  4. The departure instructions for the Cessna placed that aircraft into a direct track conflict with the runway 15 missed approach path.
  5. The aerodrome controller's decision not to increase the cut-off distance beyond 8NM resulted in a reduction of the safety buffers in the separation plan.
  6. The aerodrome controller's separation plan relied on the performance of the Cessna being sufficient to climb above the Shorts.
  7. The performance of the Cessna was not as good as that expected by the aerodrome controller.
  8. The weather conditions encountered by the Cessna were such that the pilot needed to reduce the fair weather climb performance for operational safety reasons.
  9. The coordination between the aerodrome controller and the approach controller was inadequate.
  10. The Cairns Local Instructions did not authorise the use of radar by the aerodrome controller for separation purposes.
  11. Neither the aerodrome controller nor the approach controller applied positive separation assurance techniques.
  12. Cairns tower controllers had not received adequate ongoing refresher training in emergency and/or unusual situations.

Analysis

Weather

The general conditions of low cloud and heavy rain made any visual reference unlikely for both pilots and controllers. As both crews were operating in instrument flying conditions, the chances of their making visual contact with the other aircraft were low. Therefore, the presence of a break in the cloud of sufficient size to allow such sighting was of a fortuitous nature and could not be relied on for tactical planning purposes.

Missed approach and departure procedures

These procedures were so constrained by terrain considerations that, whenever an aircraft commenced a missed approach, a conflict would occur unless the aerodrome controller could visually monitor the aircraft with any departure until a specific separation standard was achieved.

Even using the 030 degrees heading option for the departure, the missed approach procedure would have, at best, resulted in the aircraft tracking parallel to each other approximately 1 -1.5 NM apart; a situation that would still result in an infringement of separation standards if no vertical separation existed. As the terrain prevented a departure heading east of 030 degrees, the situation would have required the missed approach track to be north-west of 030 degrees to guarantee a divergence.

Air traffic control procedures

MATS 6-4-3 allowed an unrestricted departure prior to an arriving aircraft commencing final approach provided a specific lateral separation standard of a minimum of 45 degrees between the departure track and the reciprocal of the final approach track existed. If the departure heading had been between 015 and 030 degrees, this standard would have been achieved. However, because of the limitations of the missed approach track and the weather situation, the maintenance of the separation standard could not be expected and an alternative standard would need to be established.

MATS also allowed for a departure when an aircraft had commenced final approach provided a reasonable assurance existed that a landing could be accomplished or that separation standards could be applied between the aircraft in a missed approach and the aircraft desiring take-off clearance. In this case the weather precluded any guarantee of the Shorts landing and no separation assurance was in place.

It may have been possible to use the lateral separation standard of 45 degrees between tracks if the departure heading had been between 015 - 030 degrees. However, even if this option had been taken, MATS required an allowance to be made when, among other things, missed approaches were likely, and/or a faster aircraft was approaching in respect of a slower aircraft taking off. Both circumstances applied to this occurrence.

Cairns Local Instructions (TWR - 29) gave further guidance in the specific case of runway 15 when "... consideration must be given to increase the cut-off distance used between the landing aircraft; and the aircraft commencing take-off." Because the Shorts was between 9 - 7.5 NM during the time that the Cessna was processed for departure, some doubt existed as to which circumstance applied. In either case the departure was conditional on a separation standard being applied and, as the heading issued was not 45 degrees from the approach track, neither of the lateral separation standards were useable.

As the aircraft were on conflicting tracks without any vertical separation established, a radar vector may have been appropriate. The approach controller was rated to perform the task but did not have either crew on frequency. The aerodrome controller had the radio contact but was not rated to perform the task. However, as the aircraft came into close proximity, an emergency radar vector by the aerodrome controller may have increased the minimum distance between the aircraft. MATS 4-1-1 para 3.f authorises any controller to take any necessary action to ensure aircraft safety.

Separation standards

Procedural lateral separation with the final approach path was possible under the provisions of MATS but not under the terms of the departure instructions issued by the approach controller. As the tracks of both aircraft were not laterally separated (a situation that became a direct conflict when the Shorts commenced a missed approach) an alternative form of separation was required.

The aerodrome controller may use visual separation based on judgement and experience to provide initial separation until a more specific standard is achieved. However, in the prevailing weather conditions adequate visual contact with both aircraft was not possible. Therefore, this standard was not appropriate.

Radar separation of 3 NM was not appropriate as the conflict occurred within 2 NM of the aerodrome. In addition, as both aircraft were heading in the same sector of airspace, the likelihood was that the standard would not be achieved for some time. Longitudinal standards were also unlikely to be attained in the short term for similar reasons.

Vertical separation was applicable but relied on the Cessna becoming established 1,000 ft above the Shorts. As the Cessna was starting from a position below that of the Shorts, the standard was not available during the initial climb phase. A standard of 500 ft was useable initially as a form of emergency separation. However, the limitations were the same as for the 1,000 ft standard.

There was an option to amend the departure heading for the Cessna to provide initial lateral separation; the limitations of this option have been discussed above. Consequently, no separation standard existed at the time the Cessna departed and separation assurance was neither achieved nor positively sought until the conflict was unavoidable.

Aircraft performance

Although the aerodrome controller expected the Cessna to out-climb the Shorts, operational factors were such that the opposite was the case. MATS 4-1-1 paragraph 13 informed controllers of such a possibility. In addition, in the case of the Cessna, several factors in the first 4 minutes of flight indicated that operations were not as expected.

Aerodrome controller

The controller had a traffic management plan that relied on an expected aircraft performance of the Cessna and Shorts types. This expectation was based on his observations since arriving at Cairns. The plan was twofold; either the Cessna would out-climb the Shorts and vertical separation would be established, or the Cessna would reach the point at which the missed approach track would conflict with the departure track first and pass clear of that point before the Shorts entered the area of conflict. There was no consultation with the approach controller and no discussion of any alternative plan even though the weather conditions precluded visual separation as an initial standard.

As the flight of the Cessna progressed, the controller realised that the climb was not as good as expected but elected to continue with his original plan hoping that one of the alternatives would still work. Separation assurance had not been implemented.

When the crew of the Shorts reported maintaining 1,000 ft the controller established that the Cessna had left 1,500 ft, thus indicating a 500 ft emergency separation standard. However, no instruction was issued to the crew of the Shorts other than a climb to 1,500 ft. Additionally, the poor quality of the radio transmission and the mention of 1,500 (ft) by the crew should have raised sufficient doubt in the controller's mind to warrant clarification.

Although the aerodrome controller considered that the radar altitude read-out from the SD36 was erratic, other controllers expressed concern over the fact that they saw the altitudes of the aircraft indicate similar levels as they approached the point of closest proximity. When the approach controller questioned the separation status, albeit with an oblique comment, the reply was that there was "not much to do mate, ..." indicating that he had done all that was required, even though no separation standard had been achieved. However, a few seconds later he issued updated traffic information to the crew of the Shorts indicating that the other aircraft was in the same position at the same level.

The passing of traffic information when an aircraft is in cloud and heavy rain and the crew are flying the aircraft with reference to instruments, was unlikely to result in a sighting; even though it did in this case. However, passing traffic information when a near collision is imminent is sound practice.

Approach controller

The controller had been surprised when he realised that the aerodrome controller had cleared the Cessna for take-off ahead of the arriving Shorts. He realised that if a missed approach resulted, then a conflict was imminent. He assumed that the aerodrome controller had accepted separation responsibility and chose to allow him to continue with that role but made no attempt to establish what standard was being used. Even though the last known information was that the Shorts was likely to conduct a missed approach and visual separation was unlikely, no coordination was instigated to adequately determine the status of separation in his airspace.

Other controllers reported that as the situation developed, they had asked what was happening and made comments such as "do something". The reply was that the aerodrome controller was providing the separation. Eventually he could see that the radar indicated a near collision situation and questioned the aerodrome controller, but this was with very ambiguous words and when the aircraft were only 10 seconds from the point of closest proximity.

Training

The circumstances surrounding the occurrence were not often experienced at Cairns. Consequently, the combination of events were such that many controllers had never seen this scenario before and were not fully familiar with how to resolve the confliction. The procedures were such that this type of incident could have happened at any time in recent years.

Although initial training covered the procedures contained in Local Instructions, some controllers could not remember any recent "Team" discussions on unusual or emergency situations and formal abnormal situation refresher training had not been regularly undertaken.

Pilot of the Cessna

Operational decisions were taken with the safety of the flight in mind and as a result of the prevailing weather conditions; the full effect of which were not known until actually encountered.

The pilot had intended to comply with the departure instructions as he commenced take-off roll but found himself unable to continue with that plan as a result of constant turbulence and downdrafts.

Crew of the Shorts

The crew had made a standard missed approach decision and the pilot in command had intended to maintain the aircraft at 1,000 ft initially. However, the instruction to the co-pilot was made at the same time as the pilot in command was broadcasting to air traffic control. The words were heard by the aerodrome controller but not by the co-pilot. This situation led to a misunderstanding, in that the controller thought the aircraft was going to maintain 1,000 ft but the crew continued to climb to their assigned level of 1,500 ft.

Summary

Sequence of events

The Short Bros SD 3-60-300 (Shorts) was being radar vectored by air traffic control for an instrument landing system (ILS) approach to runway 15 at Cairns.

The weather conditions were fluctuating about the landing minima with low cloud and rain passing through the local area in general "stream" conditions. The automatic terminal information service was quoting a cloud base of 1,000 ft with lower patches and visibility reduced to 5,000 m in passing showers. The conditions were observed to deteriorate during periods of heavy rain showers and the air traffic control tower staff updated each crew as appropriate.

As the Shorts intercepted the final approach path at 14 NM from touchdown, the aerodrome controller informed the approach controller that the weather had deteriorated at the aerodrome and that there was a likelihood that the Shorts would carry out a missed approach. The approach controller informed the crew and transferred them to the tower frequency so that the aerodrome controller could provide timely updates of the changing weather situation.

At 0744:05 Eastern Standard Time, the pilot of a Cessna 208 (Cessna) reported ready to depart on the aerodrome control frequency and was instructed to line-up. At that time, the Shorts was approximately 9 NM from touchdown with a ground speed of 120 kts.

The aerodrome controller received a departure instruction of "Left 360 unrestricted" from the approach controller (who was also providing the departure service). The pilot of the Cessna was then given a take-off clearance in accordance with that instruction but with an additional instruction to remain on the aerodrome controller's frequency when airborne. The aircraft commenced take off roll at approximately 0745:00; when the Shorts was approximately 7.5 NM from the runway 15 threshold.

At 0745:05, the crew of the Shorts was informed that the rain was increasing at the field and that the runway lights were on stage 6; the maximum intensity.

At 0746:04, the pilot of the Cessna was asked to expedite his climb through 2,000 ft and, at 0746:30, the crew of the Shorts was cleared to land.

At 0748:29, the pilot of the C208 apologised for the slow rate of climb and commented that he was "... just doing his best". At about the same time, the crew of the Shorts commenced a missed approach and, at 0748:39, they were instructed to maintain 1,500 ft and informed that there was "... traffic abeam you now at the 9 o'clock position". That transmission by the aerodrome controller was followed, at 0748:56, by a broadcast to the pilot of the Cessna saying "... caution traffic in the missed approach".

At 0749:07, the aerodrome controller updated the traffic information to the crew of the Shorts with "... caution, the traffic is in your 12 o'clock position at half a mile". The reply was garbled and included the statement "... we are maintaining one thousand at the moment..." which was followed by words that were not completely discernible but included "... one thousand five hundred..."

At 0749:27, the pilot of the Cessna was instructed to report leaving 1,500 ft and replied that he had left that altitude. A subsequent radar analysis indicated that the aircraft was climbing through 1,550 ft at that time.

At 0749:40, the approach controller checked with the aerodrome controller to ascertain his plan for separation. The reply was that there was "... not much to do". However, at 0749:51, the aerodrome controller broadcast to the crew of the Shorts that radar indicated traffic in the same position at the same level. The reply was that the crew had sighted the Cessna and were passing that aircraft.

Radar analysis indicated that the aircraft had passed at approximately 0749:50 with a minimum horizontal distance of about 70m and a vertical displacement of between 100 - 200 ft. The required separation standard was either 3 NM horizontally or 1,000ft vertically. There had been an infringement of separation standards.

Missed approach and departure procedures

Due to the constraints of terrain surrounding the Cairns aerodrome, both the missed approach and departure procedures required tracking in a 40 degree sector to the north-east. The missed approach required an initial climb straight ahead to the Middle Marker, then a climbing left turn onto a heading of 030 degrees to intercept the 045 radial of the Cairns VOR (Very High Frequency navigation aid), with a climb to 4,000 ft or a level assigned by air traffic control.

The standard instrument departure required a left turn at the earlier of 400 ft or the departure end of the runway, onto an assigned heading between 350 - 030 degrees. The lowest altitude for radar vectoring in this sector was between 1,000ft and 3,300ft depending on the precise position of the aircraft at the time.

This combination of tracking requirements resulted in a guaranteed tracking conflict whenever a missed approach was commenced when a departing aircraft was within 3NM of the aerodrome. Furthermore, an infringement of separation standards would occur whenever a missed approach was carried out in instrument meteorological conditions without vertical separation being established.

Separation standards

Air traffic controllers were limited to a minimum altitude of 1,500 ft for terrain clearance in the case of a missed approach. To establish the vertical separation standard of 1,000 ft (or 500 ft in an emergency), a departing aircraft would have to be at or above 2,500 ft (or 2,000 ft in an emergency). When the Shorts was established in the missed approach turn, it was climbing through 700 ft while the Cessna had left 1,300 ft.

The radar standard was not achieved as the tracks crossed each other approximately 2NM north-east of the runway. As the aircraft had to track in the same narrow sector of airspace, it would have been some minutes before a radar standard could be established.

Visual separation was not an option due to the prevailing weather conditions. The aerodrome controller could not see either aircraft as they came into conflict.

Lateral separation - the Manual of Air Traffic Services section 6-4-3 stated "lateral separation is considered to exist between an arriving aircraft that subsequently commenced final approach, and a departing aircraft that has been cleared on a segregated flight path". That is, a situation where the departing aircraft will not be manoeuvring within 45 degrees of the reciprocal of the final approach path while an aircraft is on the final approach path. The assigned heading of 360 degrees for the Cessna did not comply with that standard.

Longitudinal separation standards did not apply because they required distances greater than those required for radar standards.

Aircraft performance

The Shorts, a 36 passenger aircraft, had seven persons on board and very little freight. Consequently, when the missed approach was commenced, the crew attained a rate of climb of 700 - 800 ft/min. They stated that 300 - 600 ft/min was their expected rate of climb.

The Cessna was at maximum take-off weight and, because of the heavy rain, the pilot had selected the Inertial Separation Handle to bypass mode. That operation helped to divert heavy rain droplets around the engine so that the risk of flame-out was reduced.

When airborne, the pilot of the Cessna experienced severe turbulence and downdrafts, along with buffeting from the gusty wind and heavy rain. The combination of the prevailing weather conditions and the selection of bypass mode resulted in a degraded climb performance from that normally expected. Radar analysis indicated that the Cessna had an average rate of climb of 400 ft/min from take-off to the point of closest proximity and, at times, a rate of climb near zero. The pilot stated that he expected a rate of climb between 800 - 1,200 ft/min.

Air traffic control procedures

The Manual of Air Traffic Services (MATS) section 6-4-3 specified the procedures to be applied in the case of an arriving aircraft and an aircraft taking off. It stated that "a departing aircraft may be permitted to take off during the period before an arriving aircraft will commence its final approach" but goes on to say that such take-off clearance "... is conditional upon the application of separation after take-off is commenced".

Final approach was defined as 8NM from the runway 15 threshold. The aerodrome controller may have complied with the distance requirement as the Cessna was cleared for take-off when the Shorts was approximately 8NM from the threshold.

Cairns Local Instructions (TWR - 29) reinforced the provisions of MATS in the specific instance of the conflicting missed approach and departure headings from runway 15. They stated that "... consideration must be given to increase the cut-off distance used between the landing aircraft and the aircraft commencing take-off when weather conditions are such that visual or radar separation of the overshooting aircraft and departing aircraft cannot occur". Local Instructions did not specify clearly who had the responsibility for separating the missed approach from the departing aircraft. Approach control was responsible for the airspace but the aerodrome controller had to advise the approach controller of the most appropriate heading consistent with the ability to provide separation with other airborne traffic.

Cairns controllers operated in such a way that the aerodrome controller separated an aircraft on the missed approach path with other traffic, using visual separation until an alternative standard could be achieved. As the weather conditions precluded such an option, a specific alternative was required. Tower controllers were not rated to provide radar separation and could only use the radar display "for information". However, Local Instructions specified that it was the aerodrome controller's responsibility to ensure that radar separation existed between an aircraft on short final and not yet in sight and an aircraft becoming airborne.

MATS 6-5-1 allowed a tower controller to provide an uncoordinated radar vector to initiate separation in cases such as a missed approach. However, MATS required Local Instructions to specify the details. Cairns Local Instructions did not specify any such details.

Aerodrome controller

The controller had considered extending the cut-off distance but believed that, as the Shorts had not commenced final approach, he could safely clear the Cessna for take-off. He had witnessed numerous departures by Cessna 208 type aircraft and had an expectancy that the aircraft would climb at a rate which would enable vertical separation to be easily achieved if the Shorts commenced a missed approach. He also expected the Cessna to proceed at a speed that would position that aircraft well ahead of the Shorts at the crossing point of the departure track and the missed approach path.

Although the approach controller had nominal responsibility for the airspace, the aerodrome controller had assumed separation responsibility when he retained the pilot of the Cessna on his radio frequency for departure. As the Cessna departed, the controller observed that it did not turn in accordance with the standard instrument departure instructions but continued for approximately half a mile before commencing the turn. He then noticed that the rate of climb was not as good as he had expected and, at 0746:11, asked the pilot to expedite through 2,000 ft and report leaving 2,000 ft. That instruction was to maintain his traffic management plan of achieving vertical separation with any missed approach procedure and would have provided a 500 ft emergency standard if he maintained the Shorts at 1,500 ft in the missed approach.

As the aircraft closed to within 1.5 NM, the controller gave traffic information to both crews. However, that information did not include the aircraft type, or height, or relative height. The information was only position and distance to the crew of the Shorts and included the words "... traffic abeam you now at the 9 o'clock position". That information was incorrect as the Shorts was in a left turn and the traffic was actually in the 12 o'clock position moving towards the 2 o'clock position. The pilot of the Cessna was advised "Caution, traffic on the missed approach". The controller asked the other controllers in the tower at the time for advice but they were unable, in the time available, to offer an alternative course of action.

When the crew of the Shorts made a broadcast that they were "... maintaining 1,000 (feet) at the moment..." in the middle of a transmission that was broken and partly unintelligible, the controller neither questioned the crew as to their mention of the words "... one thousand five hundred..." during that broadcast nor did he issue an altitude instruction. However, he did obtain an altitude report from the pilot of the Cessna which indicated that the aircraft had left 1,500 ft on climb. The controller's subsequent conversation with the approach controller indicated that he was satisfied with the separation standard saying "...(the Shorts) supposed to be maintaining 1,000 (ft) the other has left 1,500 (ft) ...".

The controller was of the opinion that the altitude read outs from the Shorts were varying so much that he did not know that the aircraft had not maintained 1,000 ft. Radar analysis of the readouts indicated a relatively steady increase in height over the 90 seconds from 0748:30 - 0750:00 but with two "spikes" at approximately 1,100 ft (at approximately time 0749:07) and 1,500 ft (at approximately time 0749:45).

Approach controller

The approach controller had issued the departure instruction for the Cessna believing that, as the Shorts was about 8NM from touchdown, the aerodrome controller would not depart that aircraft until after the arrival, or that the Shorts was in sight and reasonably assured of a landing. However, the terminology used by the aerodrome controller "next CYC" indicated that the Cessna would commence take off within 1 minute of the receipt of a departure instruction.

As the situation developed, the controller monitored the radio frequency of the aerodrome controller to observe the plan for separation. He had heard the requirement to remain with the tower given to the pilot of the Cessna and considered that the aerodrome controller had accepted the responsibility for separation with this action. As the radar display indicated that the aircraft were on conflicting tracks and at similar altitudes, other controllers asked what separation was being applied. The approach controller replied that the aerodrome controller was providing the separation but elected to prompt the tower with the question "you right?". This coordination occurred at 0749:40, approximately 10 seconds before the point of closest proximity, and was the first contact between the controllers since the departure instruction for the Cessna was issued.

Emergency training

The Cairns air traffic controllers had not received regular training in emergency or unusual situations. Tower controllers had last undertaken formal refresher training in October 1997. However, the aerodrome controller had been absent on recreational leave and did not attend the training. He had received formal tuition in dealing with similar circumstances during his aerodrome control training in December 1997 and January 1998.

The aerodrome controller stated that he had experienced only one missed approach due to poor weather in his 3 years at Cairns. As the incident developed, he asked for advice from his fellow tower controllers but as they were occupied with their own tasks, they were unable to give a properly considered response.

Pilot of the Cessna

The pilot was conducting a single pilot operation and had intended to comply with the requirements of the standard instrument departure by turning left at 400 ft or the departure end of the runway. However, when airborne, the initial climb did not proceed as well as expected, with severe turbulence and heavy rain buffeting the aircraft. The airspeed was not increasing as quickly as he would have liked and at the upwind end of the runway the aircraft had only reached an altitude of 200 - 250 ft. Consequently, the pilot elected to continue on runway heading until a more stable climb was achieved. The left turn was commenced at an altitude of 300 ft and an indicated airspeed of approximately 70 kts. There was no broadcast to air traffic control indicating the variation to the standard procedure.

Once the aircraft had turned onto the assigned heading of 360 degrees, the pilot made every effort to maximise the rate of climb but was limited by the aircraft performance in turbulent weather conditions. At 0748:29, he broadcast to the aerodrome controller that he was experiencing a slower than normal rate of climb.

When, at 0748:56, he was given conflicting traffic information, he attempted to sight the other aircraft but found visibility limited in cloud and heavy rain. Shortly after, the aircraft broke into a small clear patch and the pilot saw the Shorts just below and marginally to his left. He estimated that the aircraft would pass just behind his own and elected not to take any evasive action.

Crew of the Shorts

The co-pilot was the flying pilot and, as the aircraft approached the minima, the crew found themselves in cloud, heavy rain and subjected to severe turbulence culminating in their decision to commence a missed approach.

The crew's main preoccupation was to ensure the safe climb-out of their aircraft in the left turn required by the procedure and, as they were experiencing instrument meteorological conditions, their first priority was to fly the aircraft. Consequently, they did not immediately inform air traffic control of their commencing a missed approach. Before they could broadcast any details, the aerodrome controller issued an instruction for them to maintain 1,500 ft and passed traffic information. As they were still in cloud and rain, their lookout was both occasional and of limited effect.

A short time later, the controller issued an updated traffic alert indicating that the other aircraft was half a mile ahead. The response from the pilot in command was that they were maintaining 1,000 ft temporarily but still climbing to 1,500 ft as cleared by air traffic control. The pilot in command had intended to maintain 1,000 ft after the traffic information had been passed but the co-pilot did not hear the instruction as it was said during the radio broadcast to air traffic control and during a period of intense flying activity. As the pilot in command was about to reiterate the maintain 1,000 ft instruction to the co-pilot, the aircraft broke into the same clear patch as the Cessna and they saw that aircraft ahead and slightly above. The co-pilot levelled the aircraft momentarily to ensure that they would pass beneath the Cessna and then continued the climb to 1,500 ft when established clear of it.

Occurrence summary

Investigation number 199901012
Occurrence date 12/03/1999
Location 4 km N Cairns, Aero.
State Queensland
Report release date 27/03/2000
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 Short Bros Pty Ltd
Model SD3-60
Registration VH-SUR
Serial number VH-SUR
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Townsville, QLD
Destination Cairns, QLD
Damage Nil

Aircraft details

Manufacturer Cessna Aircraft Company
Model 208
Registration VH-CYC
Serial number VH-CYC
Sector Turboprop
Operation type Charter
Departure point Cairns, QLD
Destination Croydon, QLD
Damage Nil