Collision with terrain Air Tractor AT-502A, VH-MVS, near Nyngan, New South Wales, on 18 September 1997

Factual Information

Aircraft information

The aircraft was fitted with a Pratt and Whitney PT6A-45R turbine engine driving a five-bladed metal Hartzell reversible-pitch propeller. This engine-propeller combination provided the aircraft with a significantly higher performance than other models of the aircraft type that were powered by piston engines.

The pilot

The pilot was appropriately qualified to undertake the flight. Of his total flying experience, about 9,500 hours was in agricultural flying. However, he had flown only about 80 hours on turbine-powered Air Tractor aircraft, the bulk of his flying experience being on piston engine models.

Wreckage examination

Examination at the accident site revealed that the aircraft had struck the ground inverted and in a level attitude. Ground marks indicated that the aircraft was yawing right and at low forward speed at impact.

The fire destroyed the airframe. The destruction of some components of the flight control system, particularly the aileron system, precluded determination of their serviceability prior to impact.

Three blades of the propeller had failed in overload against the direction of engine rotation. The position of failure was about 200 mm from the propeller hub. The failure surfaces indicated that the blades were at a coarse pitch angle at the time of failure.

Survival aspects

The metal end fittings of the pilot's safety harness were found in the wreckage. Each was separated from the other with the latch on the locking buckle stowed in its housing, as it would be if the harness was locked. Examination of the end fittings revealed no discernible deformation on any load carrying part of the fittings, suggesting that the harness was not secured at impact.

Analysis

The witness description of the aircraft's behaviour, along with the evidence at the impact site, indicated that the aircraft probably stalled aerodynamically as the pilot reversed the direction of the procedure turn. It is likely that the aircraft was in a nose-high attitude at the time. This would explain the apparent low forward speed of the aircraft at impact. Assuming that the pilot was conducting the turns at typical altitudes, it is unlikely that there would have been sufficient height available for the pilot to recover the aircraft to normal flight. The pilot's low experience level on turbine powered Air Tractor aircraft compared with piston engine powered models may have contributed to the loss of control.

Details obtained during the investigation did not allow any conclusions to be drawn concerning the security of the pilot's safety harness at impact.

Summary

After arriving at the property strip, the pilot was briefed on the spray area by the property owner. In the meantime, the aircraft was loaded with 1,500 litres of spray solution. The pilot subsequently boarded the aircraft and was observed to secure his safety harness, and don gloves and a helmet, before departing for the task.

The spray area was about 800 m from the strip. Witnesses at the strip observed the aircraft as it began spraying and noted that the procedure turns at the end of each run were conducted at a consistent height. The turns were flown initially to the left to offset the aircraft from the previous run, and then reversed to align the aircraft for the next run. About 30 minutes after spraying had commenced, one of the witnesses observed the aircraft rolling right during a turn reversal in a procedure turn. The aircraft continued rolling until it was in an inverted attitude, and then descended into the ground where it immediately caught fire.

Occurrence summary

Investigation number 199703038
Occurrence date 18/09/1997
Location 15 km S Nyngan
State New South Wales
Report release date 01/03/1999
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 Air Tractor Inc
Model AT502
Registration VH-MVS
Serial number 502A-0178
Sector Turboprop
Operation type Aerial Work
Departure point 'Montrose', Nyngan NSW
Destination Warren, NSW
Damage Destroyed

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

Safety Action

As a result of investigation into this and similar occurrences, the Bureau of Air Safety Investigation issued the following interim recommendations to Airservices Australia:

IR970112 (issued on 14 July 1997)

"The Bureau of Air Safety Investigation recommends that Airservices Australia review the provision of air traffic services to maximise the use of the currently available radar coverage particularly on routes used by regular public transport aircraft.

The following response was received from Airservices Australia on 21 October 1997:

"Airservices Australia is reviewing the provision of air traffic services with regard to maximising the use of radar services both within and outside controlled airspace".

As you are aware, the Airspace 2000 proposal which Airservices planned to introduce on the 26th February 1998, comprehensively addresses the extension of radar services. These radar enhanced services include:

Radar Class E airspace from Cairns to Melbourne above 8,500 feet.

A Radar - Information Service (RIS) in Class G airspace within radar coverage.

The Board of the Civil Aviation Safety Authority (CASA) has deferred making a decision on the proposal. Regardless of the outcome of the Airspace 2000 review by CASA, Airservices intends proceeding with three initiatives to enhance radar services on the 26th of February 1998.

Radar Class E airspace will be introduced between 8500 feet and FL125 outside existing Class C airspace from Grafton to Canberra within radar coverage. Brisbane Enroute will provide radar services within the Class C control area steps over Coffs Harbour down to 4500 feet. Sydney Terminal Control Unit will provide radar services to 45nm Sydney in non controlled airspace on a discrete frequency. These initiatives will increase Airservices use of existing radar coverage for air traffic services. Further expansion of radar services is limited pending decisions on Airspace 2000 by CASA."

Response classification - CLOSED-ACCEPTED

IR980005 (issued on 24 March 1998)

"The Bureau of Air Safety Investigation recommends that Airservices Australia review the guidance in the MATS for the passing of traffic information by ATS personnel to ensure pilots have adequate time to assess the potential for conflict with other aircraft".

The following response (in part) was received from Airservices Australia on 27 May 1998:

"ATS Operational Policy Branch is developing comprehensive procedures for processing traffic information under the new environment".

Response classification: OPEN

IR980021 (issued on 24 March 1998)

"The Bureau of Air Safety Investigation recommends that Airservices Australia review ATS proficiency and continuation training requirements with a view to personnel undertaking specific traffic information simulator training on a regular basis".

The following response was received from Airservices Australia on 27 May 1998:

"Airservices has developed its refresher training program for delivery to operational Air Traffic Services officers to emphasise elements dealing with the provision of traffic information and actions to be taken when separation has or may have been compromised".

Response classification: OPEN

IR980059 (issued on 22 April 1998)

"The Bureau of Air Safety Investigation recommends that Airservices Australia review air traffic service procedures relating to the combining of a number of operator positions and/or frequencies with a view to reducing the impact of frequency congestion.

The following response was received from Airservices Australia on 4 June 1998:

In addition to AIC H34/97, Airservices provides direction to ATS staff regarding the use of retransmit facilities in MATS 12-4-2 which shows "To reduce frequency congestion and interference on pilot broadcasts or other pilot-to-pilot communications being used for self separation, the retransmit facility should be operated in the "OFF" mode whenever practicable."

A number of other factors, in the context of the Airspace 2000 initiatives, relating to the provision of services are currently being discussed with CASA. Implementation of aspects of these initiatives would affect not only the way services are provided but the way in which ATS frequencies are used.

Airservices will continue to monitor the effects of retransmit facilities pending resolution of a number of issues associated with the implementation of CASA's Airspace 2000 initiatives".

Response classification: OPEN

Additionally, the Bureau of Air Safety Investigation is investigating a safety deficiency relating to Air Traffic Services' responses to in-flight emergencies.

Any safety output issued as a result of this deficiency analysis will be published in the Bureau's Quarterly Safety Deficiency Report.

Significant Factors

  1. A significant number of pilots were operating on the flight service frequency, which made it difficult for crews to report their positions or exchange information for traffic avoidance.
  2. The crew of the DHC-8 did not report their intention to change flight level to the flight service officer.
  3. The crew of the C130 did not report the Mount Sandon position to the flight service officer.
  4. The crew of the C130 was unable to contact the crew of the DHC-8 to arrange separation between the aircraft, due to frequency congestion.
  5. The crew of the C130 did not report that the aircraft was maintaining FL130 to the radar controller after previously reporting leaving that level.
  6. The flight service officer did not provide directed traffic information in accordance with MATS.
  7. The flight service officer assumed that the DHC-8 had entered controlled airspace and subsequently provided unverified information to the crew of the C130.
  8. The crew of the C130 received incorrect traffic information on the DHC-8.

Analysis

The investigation revealed that a combination of traffic disposition and the use of retransmission on the FS3 frequencies created a congested radio environment for the FS3 officer. As a consequence, the provision of reports by pilots and the provision of traffic information by the officer were constrained.

Following unsuccessful attempts to obtain a clearance to enter controlled airspace from the radar controller, the crew of the DHC-8 were also unable to report to FS3 that the aircraft was maintaining FL125 due to the congestion on the frequency. Similarly, the crew of the C130 was probably unable to report the Mount Sandon position to FS3 after changing to that frequency. Provision of a position report by the crew of the C130 or notification of the change in level by the crew of the DHC-8 would have assisted the FS3 officer to better appreciate the disposition of the aircraft.

The radar controller had advised the FS3 coordinator that the DHC-8 was in non-controlled airspace at FL125 and was traffic for the C130. However, this information was provided at a time when the FS3 operator was busy with transmissions from other pilots. Despite the coordinator's efforts, he was unable to advise the FS3 officer before the latter advised the crew of the C130 that the DHC-8 was not significant traffic. The FS3 operator should have verified the situation with the radar controller or alternatively advised the crew that the position of the DHC-8 was unknown.

The crew of the C130 were aware of the oncoming DHC-8 and had remained at FL130 for a further 3 minutes while attempting to report to FS and to contact the crew of the DHC-8 to arrange separation. Once the FS3 officer told them that they could disregard the DHC-8, the crew of the C130 descended the aircraft and unknowingly placed it in conflict.

While still at FL130 in controlled airspace, the crew of the C130 was having difficulties communicating with FS3 and the crew of the DHC-8. Had the crew of the C130 advised the radar controller of their intention to maintain FL130, it is likely that the controller would have been prompted to provide greater assistance to resolve the conflict.

Summary

At 1543 Eastern Summer Time, the crew of a De Havilland DHC-8, operating under instrument flight rules (IFR), reported to the Flight Service 3 (FS3) officer that the aircraft had departed Armidale at 1543 for Sydney and was on climb to flight level (FL) 190. Two officers were operating the FS3 position: one officer was operating the radios and managing the flight progress strip display while the other was assisting at the coordination position. The crew of the DHC-8 had not been given a clearance to enter controlled airspace and consequently levelled the aircraft at FL125, which was the lower limit of the control area. The crew of the DHC-8 did not report this change of level to FS3, contrary to Aeronautical Information Publication (AIP) procedures (AIP NCTL - 4 paragraph 49.2)

While climbing to FL125, the crew of the DHC-8 was preoccupied with ascertaining the position of other traffic in non-controlled airspace on the FS3 frequency. There were between 18 and 21 aircraft on a number of retransmitted frequencies that were being monitored by FS3. Such a volume of traffic caused frequency congestion and made communication difficult. During this period, the FS3 operator was very busy providing traffic information to the pilots of IFR aircraft.

A Royal Australian Air Force Lockheed C130 aircraft, also operating under IFR, had departed Richmond for Walcha and was cruising in controlled airspace at FL130 on the reciprocal track to the DHC-8. The crew of the C130 had been cleared to leave controlled airspace on descent and was aware that the DHC-8 was opposite direction traffic below them. At 1548 the C130 crew reported leaving FL130 to the radar controller and changed to the FS3 frequency. However, to ensure that they could maintain separation with the DHC-8, they decided to maintain the aircraft at FL130 until they could establish contact with the crew of the DHC-8 on the FS3 frequency. Contrary to AIP procedures, the C130 crew did not report their intention to maintain the aircraft at FL130 to the radar controller nor did they report the aircraft's latest position of Mount Sandon to the FS3 operator. The FS3 coordinator stated that the frequency was "extremely congested" at the time.

At 1550 the crew of the DHC-8 changed to the Brisbane Centre radar control frequency in accordance with previous instructions from the FS3 officer. The crew reported their departure from Armidale and that the aircraft was approaching FL125. An airways clearance was not initially issued to the crew of the DHC-8. The Manual of Air Traffic Services (MATS 9-5-1 paragraph l) required controllers to positively identify aircraft prior to providing a radar service and to advise pilots whenever radar identification was established or lost. The radar controller did not notify the DHC-8 crew whether the aircraft was identified or not, but advised the crew of the DHC-8 that the C130 was 12 NM ahead and appeared to be maintaining FL130.

When the crew of the DHC-8 realised that a clearance was not imminent and that they were at a VFR level, they elected to descend to an IFR level, FL120. At that stage, the C130 was in controlled airspace with the crew attempting to communicate on the FS3 frequency (intended for the use by crews operating in non-controlled airspace) and the DHC-8 was in non-controlled airspace with the crew communicating with the radar controller (used by crews operating in controlled airspace).

At 1551.12, the radar controller advised the FS3 coordinator that the DHC-8 was still at FL125 and 8 NM directly ahead of the C130. The coordinator attempted to advise the FS3 officer of the situation but was unable to pass the information because of the number of transmissions from pilots. At 1551.16, the FS3 officer advised the crew of the C130 that they could disregard the DHC-8, as that aircraft was ".. well in controlled airspace". The comment implied that the DHC-8 was above the level of the C130. Based on his previous experience and understanding of the performance of DHC-8 aircraft, the FS3 officer believed that the aircraft had reached its cruising level and that it would not conflict with the C130. However, he had no ready means to confirm that the DHC-8 was in controlled airspace. This was not in accordance with the criteria for traffic assessment specified in MATS chapter 3, which stated that "..shall be passed traffic when an assessment of data indicates the possibility of a confliction, with the overriding spirit being, when in doubt advise".

At 1551.22 the crew of the C130 reported to FS3 that the aircraft had left FL130. The radar controller advised the crew of the DHC-8 that the C130 was directly ahead of them at 3 NM and suggested that they should return to the FS frequency. At 1551.43, the crew reported that they had descended to FL120 to establish 1,000 ft vertical separation with the C130 and returned to the FS3 frequency to attempt to contact the crew of the C130.

The radar controller was unsure of the intentions of the crew of the C130: consequently, he believed it was better to have the crew of the DHC-8 return to the FS3 frequency. Also, because of their proximity to each other, and because both aircraft were in or about to enter non-controlled airspace, with limited time available to relay advice, he believed that any attempt to give avoidance instructions at that stage could have resulted in a higher risk of collision. The final transmission from the radar controller to the crew of the DHC-8 was that the C130 was 1 NM ahead at FL120. The crew may not have heard this transmission as they were communicating with the crew of the C130 on the FS3 frequency.

At 1551.53, the crew of the DHC-8 was able to communicate with the crew of the C130 and they established that the C130 had just passed them. The crew of the DHC-8 reported that they saw the C130 pass to the left of their aircraft. The aircraft passed at FL120 within approximately 400 m of each other, in the cloud tops.

Occurrence summary

Investigation number 199702957
Occurrence date 10/09/1997
Location 61 km S Armidale, Aero.
State New South Wales
Report release date 23/04/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Near collision
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer De Havilland Canada/De Havilland Aircraft of Canada
Model DHC-8
Registration VH-TQF
Serial number 067
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Armidale, NSW
Destination Sydney, NSW
Damage Nil

Aircraft details

Manufacturer Lockheed Aircraft Corp
Model C-130
Registration A97-181
Sector Turboprop
Operation type Military
Departure point Richmond, NSW
Destination Walcha, NSW
Damage Nil

Boeing 737-376, VH-TJA

Safety Action

As a result of this and other incidents, the Bureau of Air Safety Investigation (BASI) examined issues associated with Airservices Australia's operation of teams in air traffic services. This examination resulted in BASI issuing the following Safety Advisory Notice to Airservices Australia on 27 January 1998:

Safety Advisory Notice SAN 970137

Airservices Australia should note the safety deficiencies detailed in this document and take appropriate action.

The safety deficiencies referred to in this document were:

  1. an undesirably low level of operational support provided by experienced controllers, including team leaders and other full performance controllers, to controllers working in operational positions.
  2. an inappropriately low level of emphasis on team development activities, such as the provision of team leader training and support, and the regular provision of team days with structured learning content for team members.
  3. performance evaluation systems for team leaders that do not ensure relevant team leader performance areas are measured, and also do not ensure that any degradation in a team leader's proficiency on operational positions will be detected.
  4. an inappropriately low level of training and development for many controllers on human factors issues, particularly those associated with inter-controller coordination and communication.

Following receipt of this safety action notice, Airservices Australia instigated an independent review of operational supervision issues in their air traffic services' activities. This review was completed on 15 October 1998. In addition, an introductory training package for team resource management has been developed and a pilot course has been conducted.

As a result of this and other occurrences, BASI is also investigating perceived safety deficiencies associated with the design of air traffic controller shift schedules, and the allocation of a controller's tasks within a shift. Any recommendation arising from these investigations will be published in BASI's Quarterly Safety Deficiency Report.

Local Safety Action

Local safety action proposed by Melbourne Enroute as a result of this and other incidents includes the production of a local instruction defining the procedures and responsibilities involved in handover/takeover situations. This procedure is currently being trialled in the Bight Group. A specific procedure has also been developed for the ADS0s outlining the steps required to process departure messages, and the required order of these steps.

Melbourne Enroute and Perth Area are currently assessing the suitability of Perth taking over responsibility for that part of Melbourne Sector 1 that is covered by Perth radar. This approach is consistent with BASI Interim Recommendation 970112 to Airservices Australia for radar to be used for air traffic control where radar coverage is available.

Significant Factors

  1. The ADSO did not send a hard copy departure message on the B737's flight.
  2. The ADSO was a trainee and was not adequately supervised.
  3. The Sector 1 handover/takeover involved poor inter-controller communication and coordination.
  4. The oncoming Sector 1 controller did not pass coordination of the B737's TAMOD position report to the Perth Outer controller.
  5. There was a lack of appropriate procedures in relation to the departure processing task and the handover/takeover task.

Analysis

Although there was no breakdown in separation, this incident involved a serious breakdown in coordination that resulted in a B737 not being under effective air traffic control from 0858 EST until after the radar return was identified at 0947. Had the Perth controller not detected the problem, there would have been a breakdown of separation. Although the two aircraft would have both been to the east of TAMOD at the time of passing, and therefore on different routes, this situation was not planned.

The incident directly resulted from a combination of active failures. The two most significant errors were: (a) the omission of a hard copy departure message via the AFTN; and (b) the omission of any coordination on the aircraft from the Melbourne Sector 1 controller.

Processing the Hard Copy Departure Message

Had the trainee ADSO sent the departure message via the AFTN, Perth control would have activated the flight progress strips and, therefore, been better prepared to detect the missing coordination on an aircraft from Melbourne Sector 1. This error consequently removed an important safety defence.

Factors that contributed to the missing AFTN message included:

  1. the aircraft movement advice form being incomplete, and therefore not providing an appropriate cue; high workload;
  2. insufficiently detailed task procedures; and
  3. a lack of direct supervision of the trainee ADSO.

It is likely that the supervising ADSO became too involved in the operation of departure processing tasks to be able to effectively monitor the trainee's performance.

Passing Coordination of the TAPAX Position Report

The omission of the oncoming Sector 1 controller to pass coordination on the B737 to the Perth outer controller meant that the Perth controller had no forewarning of the arrival of that aircraft into his airspace. Therefore, this error increased the likelihood of a breakdown of separation standards. Although the Perth controller did detect the problem in sufficient time to avoid a breakdown in separation, it is likely that such a detection would not usually occur.

Factors that contributed to the omission included the absence of clear communication between the departing Sector 1 controller and the oncoming controller as to who would pass the coordination, and the inability of the departing controller to remain available to ensure the oncoming controller was fully briefed. More specific handover/takeover procedures could have reduced the likelihood of these factors. The development of appropriate teamwork and team resource management programs would also help reduce the likelihood of such inter-controller coordination and communication failures.

The coordination omission was also partly a result of the inherent nature of the task. It was probably an action slip, or an error where the controller's actions did not proceed as planned. More specifically, the error appeared to be a substitution of one highly automatic task (asking the B737's flight crew to transfer frequency at TAMOD) for another (passing coordination on the B737 crew's TAPAX report to the Perth Outer controller). Such substitution slips are usually associated with a period of inattention or distraction. In this case, the controller may have been distracted by the call from another flight crew immediately before she performed the task. As the controller had only been working on the sector for a few minutes, she could also have been distracted by her scanning and familiarisation activities.

An increase in the likelihood of skill-based errors is often correlated with fatigue. In this case, the controller had a less than normal amount of sleep in the 2 nights prior to the incident. However, the investigation was unable to determine if fatigue influenced the controller's performance at the time of the occurrence.

There were cues available to alert the Sector 1 controller to the error, such as the times on the TAMOD strip and the absence of a tick in the last box of the TAPAX strip. However, having developed the intention to conduct a frequency-transfer task, it is unlikely that the controller would have considered checking times on a strip. In addition, research has shown that the absence of a cue (such as a tick) is often not detected. Shortly after the error occurred, the controller disposed of the flight strips and effectively removed any remaining cues she could use to detect the error.

With the introduction of The Australian Advanced Air Traffic System (TAAATS) throughout Australia in 1998 and 1999, the likelihood of this specific type of error should be reduced. Transfers of aircraft between sectors will be conducted automatically. In addition, for procedural control sectors such as Sector 1, the spatial positions of aircraft will be pictorially displayed. It is reasonable to expect that these changes will reduce the likelihood of a controller incorrectly perceiving the position of an aircraft.

Flight Levels

The westbound A320, VH-HYA, was maintaining a non-standard flight level (FL370) which resulted in an eastbound A320, VH-HYR, being given a non-standard level (FL350) for the initial level clearance. This consequential action had the effect of placing VH-HYR in direct conflict with the B737. Had standard levels been applied on the two-way route system that was under procedural control, a safety net would have been put in place. This net would have become prominent had the Perth controller not observed the radar paint of the B737.

Summary

At 0627 EST, a Boeing 737 (B737) departed Melbourne for Perth. Melbourne Sector Inner West advised Melbourne centre of the departure. An airways data systems operator (ADSO) received this information and notified Adelaide centre of the departure by intercom. He then activated the flight strips for Melbourne Sector 1 and delivered these strips to this sector. A hard copy departure message should also have been sent via the Aeronautical Fixed Telecommunications Network (AFTN) to all units affected by the flight, but this task was not completed. As a result, Perth Air Traffic Control did not receive any notification that the aircraft had departed.

For much of its flight to Perth, the B737 was on route L513 and was under the control of Melbourne Sector 1, a procedural control sector. This sector was combined with Sector 5 until approximately 0850 when it was decided to split the two sectors. The departing controller proceeded to hand over control of Sector 1 to the oncoming controller, but kept control of Sector 5.

At 0853 EST, during the Sector 1 handover/takeover, the crew of the B737 reported having passed TAPAX (a position reporting point 523 NM east of Perth) at 0852. They also reported that they were maintaining FL350, and estimating TAMOD (a position reporting point 153 NM east of Perth) at 0951. The departing controller took the position report and appropriately marked the flight strips. The report was required to be passed to the Perth Outer controller, as the sector boundary was 10 NM east of TAMOD. This coordination task was not done.

The departing Sector 1 controller later reported that he did not perform the coordination task as he assumed that the oncoming controller would do it. He also reported that he did not specifically point out the need for the oncoming controller to perform this task, but assumed that she had heard the position report and understood that it needed to be done. The oncoming controller later reported that she could not remember hearing the position report. Neither controller could recall whether the relevant flight strip had been cocked on the flight progress board to indicate that there was an outstanding task to be performed.

The oncoming controller took control of Sector 1 at 0856. Soon after taking over, Perth control contacted her to advise that an eastbound Airbus 320 (A320), VH-HYJ, was about to transfer to her frequency and that the crew would soon contact her. This crew contacted her at 0857. At 0858, immediately after taking this crew's report, the controller contacted the westbound B737's crew and advised them to contact Perth at TAMOD. This frequency-transfer task was normally performed when the aircraft was 5 minutes from TAMOD, or 0946 in this case. Shortly after performing this task, the controller removed the B737's flight strips from the flight progress board. This action was normal practice for filing the flight strips after an aircraft had left the Sector 1 area of responsibility.

At 0929 EST, another eastbound A320, VH-HYR, departed from Perth for Melbourne. The aircraft was planned on route L513 until TAMOD, before turning onto the one-way route Y53. The estimate for TAMOD was 0953. The Perth controller informed Sector 1 of the departure. He advised that the aircraft had planned FL370 but that he recommended restricting the aircraft to non-standard FL350 due to a westbound A320, VH-HYA, at non-standard FL370 and estimating TAMOD at 1006. The Sector 1 controller agreed with this restriction.

Although having the air traffic under his jurisdiction procedurally separated, the Perth Outer controller checked the radar at 0941 and observed a return approximately 220 NM east of Perth (67 NM east of TAMOD). As the displayed information was based on extreme range returns, it was considered unreliable. However, it indicated a westbound jet aircraft at FL350. The controller checked his coordinated and pending traffic, but was unable to identify the aircraft.

At 0943, Perth Outer contacted Melbourne Sector 1 to report the return and ask whether she knew its identity. The Sector 1 controller was not aware of any aircraft in that area other than HYA, the westbound A320 that was 15 minutes behind the position of the unknown aircraft. Perth suggested restricting HYR to FL330 until the problem could be rectified. Another Perth controller advised HYR's crew of the problem. At 0946, Perth Outer directed the crew to divert to the left of track, as the observed radar return's altitude was still unverified.

With the assistance of other controllers, the Sector 1 controller retrieved the used flight strips and identified the return as the B737. The relevant information was reported to Perth Outer at 0947. The aircraft was then transferred to the Perth controller.

As the A320 had been restricted to FL330 and diverted left of track, there was no breakdown in separation. The two aircraft passed each other at 0950:01. HYR passed TAMOD at 0949, and the B737 reached TAMOD at 0951. Analysis of the radar tape indicated that HYR would have reached FL350 between 0949:20 and 0950:20. The B737 was fitted with a Traffic Alert and Collision Avoidance System.

Departure Message Processing

After receiving the B737's departure notification from Melbourne Sector Inner West, the ADSO annotated the callsign, departure point, destination and departure time on an aircraft movement advice form before advising Adelaide of the departure. However, this information was not entered in the appropriate boxes on the form and the SSR code was not entered. In addition, various unnecessary items were written on the form, including the numbers of four AFTN messages that had been sent around the time that the B737's departure was being processed.

The ADSO who took the departure notification was a trainee. He was required to be directly supervised during his task performance, but this supervision was not present at the time the departure was being processed. It was later reported that workload was high at the time of the departure, and that the trainee and the supervising ADSO were both performing departure processing tasks.

Prior to the incident, the tasks required to process a departure were specified in written procedures, but they were not all specified in the same procedural documentation. The order in which the tasks should be performed was not specified in any procedural documentation.

Sector 1 Handover/Takeover

Sector 5 was in the process of being transferred from the Bight Group, which also had Sectors 1 and 4, to the Desert Group. A console for Sector 5 had been set up in the Desert Group's area, and the controllers in that group were currently being trained in Sector 5 operations. Until the transfer was completed, Sector 5 could also be operated from Sector 1's console.

Immediately after the oncoming controller took over Sector 1, the departing controller took the flight strips for Sector 5 and arranged them on the relevant flight progress board in the Desert Group. He then proceeded to conduct a training session on Sector 5 for another controller.

It is desirable for a controller to perform all outstanding tasks prior to handing over to another controller, but this is not always practical. In this case, several tasks had to be conducted during the handover/takeover and the workload level was significant. Both the departing and the oncoming controller reported that the handover of Sector 1 appeared to be well conducted. Prior to the incident, there was no written procedure that detailed all of the required tasks to be performed during a handover/takeover.

Sector Boundary

The boundary between Melbourne Sector 1 and Perth Outer was approximately 10 NM east of the reporting point TAMOD (163 NM east of Perth). The range of the relevant radar was typically 220 NM to the east of Perth between FL330 and FL370. The Perth controller was therefore able to see to approximately 50 or 60 NM east of TAMOD at high flight levels. The air route structure had been redesigned with the intention of the Perth radar being used to its full potential, but the sector boundary had not been changed.

Personnel Information

The oncoming Sector 1 controller commenced duty at 0700 on the morning of the incident. She finished duty on her previous shift at 2030 the previous night. As she lived 90 minutes from her place of work, she had only slept 5 hours during the night before the incident. Due to other factors, she had slept even less during the previous night.

In addition to not passing coordination on the B737, the oncoming controller made three minor errors during the period after she took over Sector 1 until the Perth Outer controller detected the incident. These errors were an attempt to call HYA on the wrong frequency, and two occasions of contacting the wrong Adelaide controller (as she forgot that the relevant Adelaide sectors were combined). There were no other problems noted with any aspect of her performance or behaviour during this period.

Neither of the Sector 1 controllers had received any training in the use of teamwork or team resource management skills.

Occurrence summary

Investigation number 199702768
Occurrence date 28/08/1997
Location 37 km ESE TAMOD, (IFR)
Report release date 01/02/1999
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 The Boeing Company
Model 737
Registration VH-TJA
Serial number 24295
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination Perth, WA
Damage Nil

Aircraft details

Manufacturer Airbus
Model A320
Registration VH-HYR
Serial number 622
Sector Jet
Operation type Air Transport High Capacity
Departure point Perth, WA
Destination Melbourne, VIC
Damage Nil

Auster IIIF, VH-MBA, 'Kalimna Park' Galore

Summary

As the aircraft touched down, the pilot applied power and raised the aircraft nose immediately. The aircraft became airborne at low airspeed, climbed to about 50 ft AGL before commencing a turn to the left. In the turn, the aircraft side slipped and lost altitude. The left wingtip impacted the ground, and the aircraft began rotating to the left. As the nose impacted the ground, a fire began.

The fuselage then struck the ground in a level attitude, with the aircraft travelling rearwards, tracking about 220 M, before coming to rest. The aircraft was destroyed by fire and the pilot received fatal injuries.

Occurrence summary

Investigation number 199702797
Occurrence date 31/08/1997
Location 'Kalimna Park' Galore
State New South Wales
Report release date 04/03/1998
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 Auster Aircraft Ltd
Model III
Registration VH-MBA
Serial number IIIF
Sector Piston
Operation type Private
Departure point 'Kalimna Park' Galore NSW
Destination Temora NSW
Damage Destroyed

Kawasaki G3B-KH4, VH-MTQ

Safety Action

The Bureau of Air Safety Investigation is monitoring the progress of a number of previously issued recommendations to the Civil Aviation Safety Authority. These recommendations relate to organisational checks conducted prior to the issue of an Air Operator's Certificate, on-going surveillance of AOC holders, and the training and checking procedures used to evaluate the proficiency of pilots engaged in fare-paying passenger flights.

The Bureau will also be conducting a review of aviation occurrences involving fuel starvation and exhaustion. A report of this review is due to be completed by July 1999.

Any safety output issued as a result of these deficiency analyses and review will be published in the Bureau's Quarterly Safety Deficiency Report.

Significant Factors

  1. The pilot used incorrect fuel planning data.
  2. The pilot did not fully understand the effects on fuel consumption of altitude and engine power settings.
  3. The engine failed because of fuel exhaustion.

Summary

The pilot had planned a flight from Cairns to Mt Mulligan, a distance of about 75 km, and return. Based on his flying experience on the helicopter, he assumed a fuel usage rate of 65 litres per hour. The helicopter was refuelled to full tanks (210 litres) before departure. The planned time interval to Mt Mulligan was 38 minutes, based on a true airspeed of 70 kts and a groundspeed of 80 kts. The expected groundspeed for the return flight was 60 kts.

The helicopter departed Cairns at about 1420 and arrived at Mt Mulligan 44 minutes later. The pilot then operated in the area for about 20 minutes before landing. He visually assessed the fuel contents as 136 litres before departing Mt Mulligan for Cairns at about 1620 EST. He advised air traffic services flight watch of a SARTIME of 1730. The cruising altitude was 3,000 ft. During the latter stages of the flight, when about 10 km west of Cairns, the pilot amended the SARTIME to 1740. He also had to divert south track because of cloud. At this time, the fuel contents gauge was indicating about one quarter full. A few minutes later, when the helicopter was about 3 km southwest of Cairns Airport, the engine lost power. The pilot successfully completed an emergency landing onto a suburban street.

Examination of the helicopter revealed that the fuel tanks contained 4.8 litres of fuel. (The manufacturer's data indicated that the unusable fuel quantity for the helicopter was about 8 litres.) After fuel was added to the tanks, the engine operated normally. No fault was found with any other system that might have caused the engine failure. Calculations indicated that the actual fuel usage rate was about 77 litres per hour. This was in line with data from the engine manufacturer that indicated a usage rate of 75-80 litres per hour for similar operations.

The pilot had not previously operated the helicopter on flights longer than 30 minutes or at altitudes above 2,000 ft and did not properly understand the relationship between operating altitude, power settings, and fuel consumption. This lack of understanding, combined with the fuel usage rate the pilot used in planning the flight, resulted in the fuel supply to the engine being exhausted before the flight reached its destination.

Occurrence summary

Investigation number 199702841
Occurrence date 02/09/1997
Location 3 km SW Cairns, Airport
State Queensland
Report release date 01/03/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Fuel exhaustion
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Kawasaki Heavy Industries
Model 47
Registration VH-MTQ
Serial number 2016
Sector Helicopter
Operation type Private
Departure point Mount Mulligan, QLD
Destination Cairns, QLD
Damage Nil

Boeing 747-338, VH-EBW (QF16)

Safety Action

Local safety action

As a result of their investigation into the occurrence, Aeronautical Radio of Thailand Ltd has proposed to:

  1. Issue a local instruction to prevent controllers approving climb and descent for aircraft operating in the area adjacent to the FIR boundary, or in those areas where crews of aircraft conduct frequency changes.
  2. Issue a local instruction requiring the inclusion of the KATKI position on flight progress strips for all aircraft using the intersecting routes.
  3. Amend the aeronautical charts to have KATKI annotated as a compulsory reporting point for routes G463 and B219.
  4. Review all route intersections in the FIR similar to the KATKI position and amend existing procedures if required.
  5. Review the procedural control facilities, including the provision of adequate flight progress strip bays, and the capability for continuous control frequency monitoring by the procedural controller.

Factual Information

Air Traffic Control services

Sector 3 was responsible for the provision of air traffic control in that part of the Bangkok FIR to the south of Bangkok, and for associated portions of the Phnom Penh and Ho Chi Minh FIR'S. The Sector 3 console had three positions: a radar control position with a radar display located on the left, a procedural control position in the centre, and a radar assistant position on the right. The radar controller was responsible for separating all aircraft in the sector. This included aircraft outside radar coverage. The Sector 3 procedural controller was responsible for issuing clearances using procedural control, and assisting the radar controller with flight progress strip (FPS) marking and coordination. The procedural controller was required to notify the radar controller of any changes that would affect procedural separation.

The radar controller was the only position with facilities to transmit and receive on the control frequency of 135.5 MHz. The procedural controller could monitor the frequency, but required the radar controller to transmit control instructions to aircraft operating under procedural control.

The console had been originally designed for operations utilising a flight data processor for aircraft flight information, without the need for flight progress strips. As a result, the radar operator and assistant radar positions were not fitted with flight progress strip bays. The flight data processor had subsequently proved to be less effective than planned and the sector had reverted to using flight progress strips. This required the radar and the radar assistant consoles to be fitted with temporary strip holders.

A high level of interaction and cooperation was required between the radar and procedural controllers to effectively manage the sector's airspace. The flight progress strips for each aircraft were required to be retained in the procedural display until the crew reported at the next position. This was to enable controllers to observe that an aircraft was in transit between the previous and next positions. However, due to limited space to display the strips, the Sector controllers had developed a habit of removing flight progress strips at the earliest opportunity to make space for new strips.

The strip for QFI6, annotated for the portion of the route from ALGOR to KABAS, did not include an estimate for KATKI. There were two strips for KAL362: one annotated for the portion of the route before KANTO, and one for KANTO to SINMA. The KANTO strip for KAL362 was located in the same bay as the KABAS strip for QF16. The radar controller removed the KAL362 KANTO strip from the bay after the crew reported at that position, prior to the SINMA position.

When the crew of KAL362 requested climb from FL270 to FL290, the radar controller scanned the flight progress strips at the procedural position. There was a SINMA strip for KAL362, but no other strip to indicate a possible conflict. SINMA was located east of the route of QF16. The procedural controller was carrying out coordination duties at the time, and did not hear the climb request. The radar controller then issued a clearance for the crew of KAL362 to climb to FL290, without consulting with the procedural controller.

Crew awareness

The crew of QFI6 were using the same control frequency as KAL362 when the crew of that aircraft reported at KANTO, and were subsequently approved to climb to FL290. There were reports of radio interference on that frequency, including reports of interference from aircraft operating at lower levels. The crew of QF16 did not recall hearing the crew of KAL362 request climb to FL290, nor the amended clearance and readback.

Significant Factors

  1. The design of the Sector 3 console did not allow for all relevant flight progress strips to be displayed.
  2. The radar controller removed the KANTO flight progress strip after the KAL362 crew reported at that position.
  3. The procedural controller did not hear the request for climb to FL290 by the crew of KAL362.
  4. There was no requirement for the display of KATKI on flight progress strips for all aircraft using the intersecting routes.
  5. The radar controller did not consult with the procedural controller prior to instructing the crew of KAL362 to climb to FL290.
  6. The radar controller did not ensure that vertical separation was maintained between KAL362 and QF16 while the aircraft were in an area of conflict
  7. The crew of QF16 did not hear the request and subsequent approval for KAL362 to climb to FL290.

Analysis

The procedural controller was responsible for issuing clearances to aircraft under procedural control, as was the case in this event. The role of the radar controller was to pass on the clearance to the aircraft. By not consulting with the procedural controller, the radar controller bypassed the established system of control, leading to a breakdown in safety.

The configuration of the Sector 3 console provided insufficient space to adequately display all relevant flight progress strips. As a result, controllers had developed the habit of removing strips at the earliest opportunity, thereby creating the potential for vital information to be missed.

The KANTO flight progress strip for KAL362 should have been retained on the procedural board until the crew reported at SINMA, the next position. The removal of the KANTO strip by the radar controller removed the only reminder available to all controllers that the intended tracks of KAL362 and QFI6 would cross.

Inclusion of the KATKI position on all flight progress strips for aircraft using the intersecting routes would have enabled controllers to more readily assess separation requirements in the procedural airspace. If the strips had required the KATKI position it is probable that the details for QFI6 and KAL362 would have been displayed under the same designator on the board, allowing controllers to recognise the potential conflict.

The inability to monitor the control frequency while conducting coordination reduced the likelihood of the procedural controller maintaining a complete appreciation of the disposition of traffic.

The reason why the crew of QFI6 did not hear the transmissions regarding KAL362 climbing to the same level, while operating on the same frequency within direct line of sight, could not be determined.

Summary

QFI6, a Boeing 747, had departed Bangkok for Melbourne and was tracking southbound on airway G463 at flight level (FL) 290. The aircraft was in contact with Bangkok Area Control Centre (BKK ACC) Sector 3 on 135.5 MHz. Sector 3 was a combined radar and procedural control sector. At 0212:54 QF16 reported passing ALGOR at FL290, estimating KABAS, the flight information region (FIR) boundary, at 0221. Just prior to reaching KABAS, the aircraft would pass the intersection of G463 and B219 at KATKI. These positions were all located beyond radar coverage, over international waters, within the procedural control portion of BKK ACC Sector 3 airspace.

A Korean registered Boeing 747, KAL362, had departed Kuala Lumpur for Seoul, tracking via B219 at FL270. Approaching KANTO, located to the west of KATKI, the aircraft was transferred to the BKK ACC. The crew of KAL362 contacted Bangkok Sector 3 on 135.5 MHz and reported passing KANTO at FL270, estimating KATKI at 0219, and requesting climb to FL290. The next reporting position was SINMA, to the east of KATKI. At 0217:20 Bangkok Sector 3 cleared KAL362 to climb to FL290. KAL362 reported leaving FL270 for FL290. At 0220:21 the pilot in command of QF16 advised the Sector 3 controller of having received a traffic alert and collision avoidance system (TCAS) traffic advisory (TA), and that the aircraft had been climbed to FL300 to avoid a collision with KAL362, but was now descending to FL290.

The crew of QF16 had received a TCAS TA, followed by a resolution advisory (RA) commanding a climb to avoid climbing traffic some 800 ft below. Each crew sighted the other aircraft. The KAL362 crew also received a TCAS TA, followed by a TCAS RA commanding a descent. The crew of KAL362 did not report a traffic confliction.

An investigation carried out by Aeronautical Radio of Thailand Ltd, the Thai air traffic control organisation, indicated that KAL362 was incorrectly given a clearance to climb to FL290 by the Bangkok Sector 3 controller, and that the crews of both QF16 and KAL362 were acting in accordance with the clearances issued to them. The minimum required distance between the aircraft was 1,000 ft vertical separation, or a lateral separation of not less than 15 minutes between their estimated times of arrival at KATKI, the intersection of their intended flight routes.

In accordance with ICAO Aircraft Accident and Incident Investigation Annex 13, paragraph 5.3, the circumstances of this occurrence provide for the State of Registry to institute and conduct any necessary investigation. After consultation with the Korean authorities it was agreed that BASI would take responsibility for the ongoing investigation.

Occurrence summary

Investigation number 199702691
Occurrence date 20/08/1997
Location KATKI
State International
Report release date 01/11/1998
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-EBW
Serial number 23408
Sector Jet
Operation type Air Transport High Capacity
Departure point Bangkok, THAILAND
Destination Melbourne, VIC
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration HL-7476
Sector Jet
Operation type Air Transport High Capacity
Departure point Kuala Lumpur, MALAYSIA
Destination Seoul, Republic of Korea
Damage Nil

Cessna 210M, VH-NXC

Significant Factors

The following factors were determined to have contributed to the accident.

  1. Weather conditions were deteriorating with the passage of the cold front precluding continued VFR flight.
  2. The pilot had minimal experience with flight in actual instrument meteorological conditions.
  3. The turn was conducted at low altitude in deteriorating weather requiring the pilot to fly with sole reference to instruments.

Analysis

Witness reports indicate that the pilot had established the aircraft below the cloud layer some distance from Jerilderie. The most likely reason for this was in order to make a visual approach to Jerilderie. However, in the area of the cold front, instrument meteorological conditions extended from the base of the cloud layer to the ground. With visibility rapidly reducing, the pilot had the option of continuing straight ahead and climbing in instrument meteorological conditions to the lower safe altitude of 3,300 ft or turning back to remain in visual conditions.

The pilot initiated a left turn and entered instrument meteorological conditions close to the ground. The turn would have required the pilot to fly with sole reference to flight instruments. The transition from visual flight to flight by sole reference to instruments may take several seconds, and an aircraft in a turn will generally loose altitude until the pilot takes corrective action. However, as the aircraft was at low altitude when it began the turn, it probably struck the ground before the pilot had completed his transition to instrument flight.

Although the pilot held an instrument rating, he had minimal experience of flight in actual instrument meteorological conditions. He may not have experienced the conditions that confronted him on this occasion. The combination of rapidly deteriorating weather, gusting winds and low altitude in conjunction with low experience and recency with actual flight in instrument meteorological conditions, would have required a high level of skill and experience.

Summary

On the morning of the accident, the pilot reported for duty between 0630 and 0645 in order to have his aircraft prepared by 0700 for the day's task. The aircraft had been refuelled the night before, as was the company standard practice. After loading the freight onto the aircraft, he departed Wagga for Jerilderie at 0804 with an estimate for Jerilderie of 0845. The aircraft had full fuel and 115 kg of freight. The flight was a standard company "Run 46". The flight plan indicated that the flight was to be conducted in the IFR category at 4,000 ft with a minimum safe altitude for the route to be flown of 3,300 ft.

At 0838 the pilot contacted Melbourne Flight Service (FS) and advised that he was 15 miles east of Jerilderie and would commence descent in one minute. FS responded that there was no reported IFR traffic. There was nothing further heard from the pilot after he acknowledged this transmission.

An eyewitness working near the maintenance shed on the property Bungoona, under the flight path and north of the accident site, observed the aircraft at an estimated altitude of 100 m (328 ft). The witness described the weather conditions as misty rain, like a very thick fog or low cloud. This observation is consistent with other witnesses in the vicinity of the accident site who heard but did not see the aircraft. It was observed to bank to the left and the witness lost sight of it as it passed behind the shed. He heard an explosion, ran to the other side of the shed and saw a ball of smoke. The time of the aircraft impact was approximately 0843.

Examination of the accident site and wreckage found that the aircraft had initially struck a small tree, before impacting the ground in a left turn with 13 degrees angle of bank and 52 degrees nose down. The aircraft broke up initiating a fire that consumed the fuel and much of the wreckage and freight. The centreline of the wreckage splay was 061 degrees magnetic, and the wreckage trail was approximately 60 m in length, starting from the impact crater.

Examination of the wreckage did not find any pre-existing defects or malfunctions that would have precluded other than normal operation. The maintenance records showed that the aircraft had completed periodic maintenance on 9 June 1997. There were no outstanding maintenance action items at the time of the accident. The aircraft was due to undergo scheduled maintenance later in the week of the accident. Impact marks on the propeller and the nature of the blade damage indicated that the engine was operating under power at impact.

The pilot was the holder of a Commercial Pilots Licence, and he was appropriately qualified for the flight. He was issued with an initial instrument rating on 15 December 1996 for single engine aircraft. He subsequently gained a Multi Engine Command Instrument Rating on 17 June 1997. He had accrued approximately 563 hours total flight time, with approximately 58 hours flight time using instruments as a sole reference. This information was obtained from the company computer "Duty Flight Times" log, as the pilot's logbook was destroyed in the accident. There were no entries for hours flown since 17 August 1997.

The specialist Bureau of Meteorology report, advised that conditions at the time of the accident were a cold front passing through the Deniliquin/Jerilderie district. The frontal change had passed through Jerilderie at 0843 hours EST and would have been approaching the accident site. The wind was 270 degrees magnetic, 15 gusting to 25 knots with some localised moderate turbulence associated with the passage of the change. The visibility was 4,000 m reducing to 2,000 m with moderate showers and light rain. The temperature was 8 degrees C and the barometric pressure was 1020 hPa.

The calculated aircraft weight at take-off, was 1477 kg with a maximum allowable weight of 1724 kg. The aircraft was within the weight and centre of gravity limits at the time of the accident.

Jerilderie aerodrome does not have a published instrument approach procedure. If the pilot was unable to make an approach in visual conditions, the company policy was for the pilot to proceed to Deniliquin.

Occurrence summary

Investigation number 199702713
Occurrence date 26/08/1997
Location 16 km E Jerilderie, (ALA)
State New South Wales
Report release date 14/03/1998
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Cessna Aircraft Company
Model 210
Registration VH-NXC
Serial number 21062592
Sector Piston
Operation type Charter
Departure point Wagga, NSW
Destination Jerilderie, NSW
Damage Destroyed

Boeing 747-312, VH-INJ

Safety Action

As a result of the investigation into this occurrence, the Bureau of Air Safety Investigation issued the following Interim Recommendation on 16 September 1997:

"IR970138

The Bureau of Air Safety Investigation recommends that Boeing Commercial Airplane Group issue service information and appropriate corrective action to applicable B747 operators requiring fleet checks for:

  1. correct placement of aileron control cables on the cable drum located at WS776.98; and
  2. correct installation of aileron control position decals at WS767 and WS780".

Boeing response
The Boeing Commercial Airplane Group response, dated 13 November 1997 stated:

"The reference cover letter provided a copy of your report of an incident involving a 747-300 airplane, Serial Number 23029. The report indicates that one of the left aileron cables was broken during taxi prior to departure. The report stated that the aileron cable failures may be due to misrouting which may occur as a result of incorrectly installed markers. A check by the Australian Bureau of Air Safety Investigation found eight airplanes with incorrectly installed markers.

Your report recommended that Boeing initiate a fleet check for proper placement of the aileron control cables at Wing Station (WS) 776.98 and correct installation of aileron cable markers at WS767 and 780.

It has not been determined whether the incorrect marker installations occurred during or after manufacture. As a result of these findings, we plan to issue a service bulletin to 747 operators recommending fleet checks of all 747 airplanes prior to Line Position 1130, except Line Position 1122, for

  1. Correct routing of aileron control cables on the aileron cable drum located at wing station 777
  2. Correct installation and replacement as required, of aileron cable position markers at wing station 767 and wing station 780

Airplane Line Position 1130 was delivered in September 1997. Airplane Line Position 1122 was checked at Boeing. A review of the applicable engineering drawings shows that the marker installation and cable installation drawings are correct, and have always been correct. In addition, a check of airplanes in the factory and on the flight line indicates that both the markers and cables are currently being installed per drawing".

BASI response status: Closed - Accepted

Subsequent safety action

Boeing issued Service Bulletin 747-27-2367 (Flight controls - aileron - aileron control cable inspection and control cable marker inspection, replacement) on 25 June 1998.

As a result of the Bureau's interim recommendation, the US National Transportation Safety Board (NTSB) conducted an independent review of the circumstances of this occurrence and subsequently issued recommendation A-98-6 to the US Federal Aviation Administration (FAA) on 3 February 1998. This recommendation stated:

"The National Transportation Safety Board recommends that the Federal Aviation Administration:

Issue an airworthiness directive to require operators of Boeing 747 airplanes, produced before production line number 1130, to conduct a one-time inspection of the aileron control system to ensure correct routing of the aileron control cables on the aileron cable drum located at wing station (WS) 776.98 and correct installation of aileron cable decals at WS767 and WS780 at the earliest possible inspection interval".

Significant Factors

  1. The markers which provided visual guidance for the installation of the aileron control cables were transposed.
  2. The aileron control cables were incorrectly installed.
  3. Accelerated wear of the cables resulted in premature failure.

Analysis

The transposition of the markers provided incorrect guidance for the installation of the cables to the control drum. The two top cables then interfered with each other and resulted in an accelerated wear rate and subsequent cable failure. As the cable control drum area was difficult to see, and the aileron system operated correctly during funtional testing, incorrect installation of the cables was difficult to detect.

Summary

While taxiing for departure, the crew of the Boeing 747 selected the flaps to the take-off position. As the flaps extended, the left outboard aileron deflected to the full down position. The aircraft returned to the gate for rectification.

Investigation revealed that the left aileron cable (AA-11), which connected the inboard aileron quadrant to the aileron cable drum at wing station (WS) 776.98, had failed immediately outboard of the cable drum. The adjacent cable (AB-13), which connected the outboard aileron quadrant to the aileron control drum, was frayed at a location consistent with having been in contact with the other cable. The aileron cable drum had four grooves to accommodate the four separate aileron cables which ran inboard and outboard from the drum and connected to the inboard and outboard aileron quadrants. Markers were installed at the WS767 and WS780 locations to provide visual guidance for the routing and attachment of the aileron cables to specific grooves on the cable drum.

The aileron control drum forward guide pin was bent and displayed evidence of abrasion from interference by the cables. There was also abrasion to the top two grooves of the cable drum. Further examination revealed that the two aileron cable markers (decals) attached to the aileron drum's inboard and outboard mounting brackets at WS767 and WS780 were installed incorrectly. The marker for WS767 was fitted at WS780 and vice versa.

The aircraft had been manufactured in 1983 and had operated 62,399 hours to the time of the incident. Since 2 June 1997, when both cables were changed due to wear, the aircraft had operated 1,022 hours. The appropriate dual certifications, for the aileron control system, had been carried out at that time.

The investigation determined that another aircraft in the operator's fleet had had the same aileron cables changed, due to fraying and wear, about 12 months prior to the incident. This aircraft was inspected, and it was found that the aileron cable markers at WS767 and WS780 were also transposed.

The investigation also found that eight other aircraft, from various operators, had aileron cable markers incorrectly installed at the WS767 and WS780 locations. However, it was not possible to determine if the markers had been transposed during, or after, aircraft manufacture.

Occurrence summary

Investigation number 199702693
Occurrence date 20/08/1997
Location Brisbane, Aero.
State Queensland
Report release date 01/02/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Flight control systems
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-INJ
Serial number 23029
Sector Jet
Operation type Air Transport High Capacity
Damage Minor

Boeing 737-476, VH-TJO

Safety Action

As a result of the investigation, the company operating the A320 has amended its flight-planning process by making a modification to the flight-planning system. In the 6 months following the amendment's implementation, manoeuvring times remained within the working tolerances of position reporting.

As a result of this occurrence, the Bureau of Air Safety Investigation is currently investigating a perceived safety deficiency. The deficiency identified relates to the validation of air traffic services' flight progress strip data for aircraft operating outside radar coverage.

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

Factual Information

Radar

The Adelaide radar did not provide reliable coverage on air route T134. It normally gave coverage for aircraft over Portland and for a few miles east of SUBUM, but only provided intermittent coverage for the remainder of the route segment.

Radio

As air route T134 was predominantly outside VHF coverage, the route was designated for HF operation. The air traffic service unit responsible for HF communication was Perth International Flight Service. This limitation resulted in a delay in passing information between the controller and the crew of the B737 because the flight service officer was the intermediary for all radio transmissions.

Flight planning

The company flight plan for the A320 included a manoeuvring time of 10 minutes at the departure aerodrome. This time was estimated by the flight planner, using a computerised flight planning system, as that required for manoeuvring prior to setting course after the aircraft had become airborne. However, the flight plan indicated the time as an elapsed time from airborne to abeam/overhead Melbourne airport. The air traffic control strip printing system did not provide for a specific manoeuvring segment. Consequently, it added the 10-minute manoeuvring time to the 12-minute flight-planned time to the first enroute navigation aid.

Having added this 10-minute interval to the departure time, all the flight progress strips for the A320 therefore indicated position estimates which were approximately 10 minutes later than the corresponding flight-planned estimates.

The manoeuvring time was introduced by the company to allow for the time between becoming airborne and setting course, which varied depending on considerations such as runway direction, standard departure instructions and wind velocity. The flight crew had the same initial flight-plan information as air traffic control. However, the crew updated their plan to reflect the actual time at which the aircraft set course.

The B737 was operated by a different company and the flight plan did not include provision for a manoeuvring time. The flight progress strip estimates were therefore within the normal tolerance of plus or minus 2 minutes.

Pilot reporting

While under radar observation, pilots were not required to report their position as the controller could see that the aircraft was at the reporting point. If there was a difference between the estimated and actual times of arrival, then it was noticed by both parties and independently corrected. Under these conditions separation standards relied on radar.

When under procedural control, separation standards were based on estimated times of arrival at the reporting points and pilots were required to advise air traffic control of any variation of more than 2 minutes. Separation standards were devised to allow for these variations. Controllers crosschecked known times, as reported by pilots, with the flight plan time intervals to provide a check on the estimated time of arrival for the next position. If this crosscheck was within 2 minutes of the pilots estimate, no further action was required.

Significant Factors

  1. The flight plan for the A320 contained a manoeuvring time for the aircraft prior to setting course.
  2. The air traffic control strip printing system was unable to allow for a discrete manoeuvring time in the strip preparation.
  3. The Melbourne Sector 4 controller did not conduct a crosscheck calculation on the flight progress strip notation for the A320's estimated time of arrival at SUBUM.
  4. The Adelaide Sector 4 and Melbourne Sector 1 controllers did not initiate any check action for the observed significant difference in the time interval for the A320 between Portland and SUBUM.
  5. Air traffic control procedures were such that there was no assurrance that the flight crew's estimated times were the same as those being used by ATC to provide procedural separation.

Analysis

Flight planning

The air traffic control strip printing system's interpretations of the A320's flight plan led to a latent error in the flight progress strips for the A320 that was not present in the B737 strips. The system defence to negate this error was removed when the Melbourne Sector 4 controller did not update the flight progress strip estimated time for the SUBUM position.

Air traffic control procedures

Once the Melbourne Sector 4 controller had read the flight plan estimated time for the A320 at SUBUM, the coordination procedures were such that this incorrect estimate was passed to Adelaide Sector 4 and then from Adelaide Sector 4 to Melbourne Sector 1 without further check. Consequently, when coordination was required to allow the climb of the B737, the two controllers concerned had incorrect information. They did not question the information because it had been based on a radar observation.

Air traffic controllers

Although the flight progress strips showed that a longitudinal separation standard existed, the Melbourne Sector 4 controller did not review the situation before transferring the aircraft to Perth International HF. However, a scan of the strips should have revealed the error because the flight-planned time for the route segment was 45 minutes which, when added to the known time over Portland, would have given an estimate for SUBUM of 1447 rather than 1500.

The decision by the oncoming Adelaide Sector 4 controller to check his longer-range radar display, detected the actual position of the A320 on air route T134 and enabled him to implement remedial action.

Pilot reporting

The aircraft passed over the last radar-observed position and the crews would have made estimates for SUBUM, but were not required to report those estimates to air traffic control. The controller also made estimates for SUBUM and based a procedural separation standard on those estimates. He had no need to check those estimates with the pilots or any other controller. Consequently, when the error was made, there was no crosscheck with which to provide a safety net.

Both flight crews were operating within 2 minutes of their corrected estimates, based on their actual times at Portland, and therefore were not required to report any minor changes.

Consequently, the crews and the controllers were working a procedural standard from two different time bases, neither of which had been crosschecked with the other. In a procedural environment, pilots and controllers must have a single datum on which to base their reporting and separation.

Summary

The Boeing 737 (B737) had departed Sydney for Perth and the crew was maintaining the aircraft at flight level (FL) 280. The planned route was to track overhead Portland, Vic., then via air route T134 across the Great Australian Bight. The reporting point SUBUM was located on air route T134, approximately 220 NM south-south-west of Adelaide.

As the aircraft proceeded towards Portland, it was being radar monitored by the Melbourne Sector 4 air traffic controller. Flight crews were not required to report their positions while under radar observation. Accordingly, the time at which the aircraft was overhead Portland was recorded on the air traffic control flight progress strip by the sector controller, who then calculated an estimated time of passing SUBUM. This estimate was based on the flight-planned time interval from Portland to SUBUM and the actual time at which the controller saw the aircraft pass over Portland. The report was then coordinated to Adelaide Sector 4, which had jurisdiction for the route segment to SUBUM.

The Airbus A320 (A320) departed Melbourne for Perth and was tracking to intercept air route T134 via Portland. The crew was maintaining the aircraft at FL310.

The flight progress strips displayed information obtained from the respective company flight plans and showed that the B737 was estimating Portland at 1355 EST and SUBUM at 1444. They also showed that the A320 was estimating Portland at 1415 and SUBUM at 1500.

The Melbourne Sector 4 controller observed the B737 pass Portland at 1357 and, based on that observation, estimated that the aircraft would be approximately on time at SUBUM and elected not to change the estimated time of 1444. The position report was coordinated with Adelaide Sector 4. Air traffic control procedures allowed for a difference of up to 2 minutes between pilot and controller estimates without requiring a cross-check.

A short time later, the Melbourne Sector 4 controller assessed that the A320 passed over Portland at 1402 (13 minutes ahead of the estimate) but due to other duties, did not immediately notate the flight progress strip or coordinate this position with Adelaide Control.

At 1404, the Melbourne controller realised that he had not informed the Adelaide controller of the A320's Portland position report and commenced the coordination process. He reported the time at Portland as 1402 and the level as FL310. At this moment he realised that he had not made a calculation for the SUBUM estimate and used the estimated time of arrival as written on the flight progress strip as his revised estimate. This action resulted in his flight progress strip indicating that the A320 was going to be "on time" at SUBUM despite being 13 minutes early at Portland.

Communications for both aircraft crews were then transferred to Perth Flight Service on high frequency (HF) radio.

The Adelaide Sector 4 controller accepted the coordination from Melbourne Sector 4 on face value because the Melbourne controller was required to check the accuracy of data he was coordinating. The Adelaide Sector 4 controller checked his flight progress strips and noticed that the A320 was early at Portland but estimated to be "on time" at SUBUM. He considered that this discrepancy was probably due to a flight planning error that had been corrected by the Melbourne controller. His decision was influenced by the fact that both aircraft were estimated to be "on time" at SUBUM. He also considered that as they were vertically separated any error in the estimated times would not be significant, and chose not to pursue the matter any further.

The Adelaide Sector 4 controller then coordinated the Portland position details, including the estimated times of arrival at SUBUM, with Melbourne Sector 1, the control position for air route T134 from SUBUM. As a consequence, Melbourne Sector 1 had flight progress strips that indicated both aircraft being "on time" at SUBUM.

At 1444, the Perth Flight Service officer contacted Melbourne Sector 1 with the position report at SUBUM from the crew of the B737. This report included a request for a climb to FL310. As such a climb would negate vertical separation, the controller was required to establish a 10-minute longitudinal separation standard in order to approve the request. As the flight progress strips indicated estimates for SUBUM at 1444 and 1500, this standard appeared to have been achieved. However, because the B737 had only just entered his area of responsibility, he was required to check with the previous sector (Adelaide Sector 4) before authorising such a change. There had been a change of personnel at Adelaide Sector 4 and, as the oncoming controller also had the same time indications as the Melbourne controller, he agreed to the change and the crew of the B737 was instructed to climb to FL310.

After approving the climb, the Adelaide controller decided to check his radar display on the maximum range and saw that the A320 was only 30 seconds east of SUBUM. He immediately contacted the Melbourne Sector 1 controller to inform him of the confliction.

The Melbourne Sector 1 controller contacted Perth Flight Service and issued an instruction for the crew of the B737 to descend to FL290. Because of the amount of coordination required, it took almost 3 minutes to translate the Adelaide controller's observation into an acknowledged instruction for the B737 to descend. As the B737 had reached FL300 before the crew received the instruction to descend, and as the vertical separation standard was 2,000 ft, an infringement of the separation standards had occurred.

Occurrence summary

Investigation number 199702620
Occurrence date 17/08/1997
Location 6 km S Subum, (IFR)
State South Australia
Report release date 01/12/1998
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 737
Registration VH-TJO
Serial number 24440
Sector Jet
Operation type Air Transport High Capacity
Departure point Sydney, NSW
Destination Perth, WA
Damage Nil

Aircraft details

Manufacturer Airbus
Model A320
Registration VH-HYK
Serial number 157
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination Perth, WA
Damage Nil

Collision with terrain Piper PA-23-250, VH-ABX, 4 km north of Merriwa, New South Wales

Summary

The aircraft had taken off for a flight of about 2 hours. The pilot was the only occupant. The planned flight had been conducted several times in the past and it was the pilot's habit to fly over a relative's house about 6 km south of the airstrip before setting course and climbing to cruise altitude. On the accident flight, one eyewitness thought the aircraft initially seemed to be flying lower than it had on previous occasions.

Two witnesses about 4 km to the south of the crash site did not see the aircraft but heard its engines. Both of these witnesses reported that the engines sounded normal and that they seemed to be operating at high power. A short time after first hearing the aircraft noise, one witness heard three bangs in quick succession and saw smoke rising in the near distance. When he realised, he could no longer hear the sound of the aircraft, he notified emergency services.

A search was begun immediately, and the crew of a rescue helicopter subsequently sighted the wreckage. The pilot was found to have sustained fatal injuries. The aircraft was not fitted with an Emergency Locator Beacon (ELT).

The weather at the time was reported to be fine, with ceiling and visibility unlimited. Wind was reported as light and variable, and the temperature was about 5 degrees Celsius.

The aircraft had impacted the ground on a ploughed paddock, about 7 km from its take-off point, in a high-speed, shallow angle, right-wing-low attitude. The aircraft was destroyed on impact.

There was no evidence found at the crash site to indicate that the aircraft was other than capable of normal operation at the time of the accident. Because of the nature of the accident, it appeared that the pilot had become incapacitated or distracted shortly after take-off, resulting in an uncommanded descent into the ground. However, no conclusive indications of incapacitation were found during a post-mortem examination of the pilot.

Occurrence summary

Investigation number 199702473
Occurrence date 02/08/1997
Location 4km N Merriwa
State New South Wales
Report release date 25/03/1998
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 Piper Aircraft Corp
Model PA-23
Registration VH-ABX
Serial number 27-3650
Sector Piston
Operation type Business
Departure point Borah, NSW
Destination Bourke, NSW
Damage Destroyed