International

Boeing 747-438, VH-OJL

Summary

A Boeing 747-438 (north-east bound B747) was travelling on air route B200 within the Tahiti flight information region (FIR) at flight level (FL) 330 and was assigned FL350 by Tahiti air traffic control. When the aircraft was at FL339, the crew reported that they observed a traffic alert and collision avoidance system (TCAS) indication of another aircraft. That aircraft was a Boeing 747-400 (south-west bound B747) that was travelling in the opposite direction at FL340 also on air route B200, approximately 40NM ahead. The crew of the north-east bound B747 immediately descended to FL330. However, there was an infringement of separation standards.

The air traffic controller had planned to assign FL350 to the crew of the north-east bound B747 to maintain a separation standard with a third B747 travelling on B200 at FL330 in the opposite direction. However, FL350 was not available to the north-east bound B747 crew until the controller in Tahiti could established a separation standard with the south-west bound B747 travelling in the opposite direction at FL340.

The controller had prepared a pre-formatted controller-pilot data link communication (CPDLC) message for transmission to the crew of the north-east bound B747. CPDLC is a `means of communications between a controller and pilot using data link for [Air Traffic Control] communication' (ICAO Doc 4444 ATM/501 1-5). The message was a clearance that instructed the crew to `climb to and maintain FL350'. The controller prepared the message in advance. That was reported to be a common practice and assisted with workload management. The controller intended to send the message to the crew of the north-east bound B747 once they had passed the south-west bound B747 and a separation standard had been established. However, he unintentionally sent the message before the two aircraft had passed. On receipt of the clearance to climb, the north-east bound B747 commenced climb to FL350.

The controller immediately realised the error. He reported that he had made seven unsuccessful attempts to contact the crew of the north-east bound B747 using `selcal'. Selcal is a coded tone sent to a specific aircraft that indicated to the crew that an ATC unit was attempting to contact them via HF radio. The crew of the north-east bound B747 reported that they did not receive an indication that the controller was attempting to contact them via selcal and did not reply. The controller eventually sent another CPDLC message to the crew instructing them to 'maintain FL330 due traffic'. The crew of the north-east bound B747 acknowledged receipt of that CPDLC message. They reported however, that they had already commenced descent to FL330 when they initially observed the south-west bound B747 on the TCAS.

Air traffic controllers used automatic dependent surveillance (ADS) to verify the position of appropriately equipped aircraft operating within the Tahiti FIR in accordance with the South Pacific Operations Manual (SPOM). The SPOM detailed the procedures and requirements applicable in South Pacific FIR's for ADS approved aircraft and applied within the Tahiti FIR. ADS provides data, including position and altitude information, from navigation equipment on-board an aircraft to air traffic control via a data link. The information is updated at specified time intervals known as the periodic reporting rate. The periodic reporting rate for ADS reporting in the Tahiti FIR was 30 minutes.

Despite the unintentional clearance issue, the controller did not realise that there had been an infringement of separation standards. He had received an ADS report from the north-east bound B747 that confirmed the aircraft was level at FL330, before he sent the clearance to climb, and he received a report from that crew, subsequent to the occurrence, confirming that they were level at FL330. There were no ADS reports from the north-east bound B747 to Tahiti ATC when the aircraft was changing levels. The controller was not aware that the north-east bound B747 had left FL330 and, therefore, was not aware there had been an infringement of separation standards.

Preparation of the CPDLC message in advance may assist controllers with workload management. However, controllers need to exercise care and ensure that pending messages are not unintentionally sent.

The aircraft operator could not determine why the crew of the north-east bound B747 did not receive an indication that the controller was attempting to contact them using selcal. The selcal equipment on board the aircraft was operational before and after the occurrence, although Tahiti air traffic control had reported degraded HF communication on the night of the occurrence.

Occurrence summary

Investigation number 200200190
Occurrence date 08/02/2002
Location PUMIS, (IFR)
State International
Report release date 22/10/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-OJL
Serial number 25151
Sector Jet
Operation type Air Transport High Capacity
Departure point Auckland, New Zealand
Destination Los Angeles, United States
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration ZK-NBW
Sector Jet
Operation type Air Transport High Capacity
Departure point Los Angeles, United States
Destination Auckland, New Zealand
Damage Nil

Boeing 747-4H6, VH-OED

Significant Factors

The controller issued an incorrect climb instruction.

Analysis

The negative response `UNABLE' from the controller to the crew's request for a higher level, in accordance with the SPOM, would have reduced the possibility of error in the pre-formatted CPDLC message selected by the controller for transmission to the crew of OEB.

The use of HF radio and CPDLC combined with a high controller workload and similar radiotelephony callsigns of the two aircraft involved in the communications exchanges possibly contributed to the confusion to which the controller referred and may have resulted in the transmission of the incorrect CPDLC message.

When an individual controller combines a number of positions, diverse scenarios and increasing workloads can quickly distract controllers. Controllers and supervisors need to be vigilant so that ATC positions can be separated to facilitate effective workload management.

The monitoring of TCAS and high situational awareness by all the crews involved proved to be an effective defence for the aviation system.

Summary

A Boeing 747-48HE registered VH-OEB (OEB) was en-route from Los Angeles, USA to Auckland, New Zealand was maintaining flight level (FL) 330 as assigned by Tahiti air traffic control (ATC). A Boeing 747-4H6 registered VH-OED (OED) was en route from Auckland to Los Angeles and was also maintaining FL330. The crew of OEB reported that they observed, on their traffic alert and collision avoidance system (TCAS), another aircraft that was on a reciprocal track at the same level (OED). The crew of OEB turned their aircraft right 15 degrees and descended to FL325. The crew of OED later reported that they observed, on their TCAS, another aircraft that was on a reciprocal track at the same level (OEB), and climbed their aircraft to FL333. A third aircraft, a Boeing 747, was en-route from Los Angeles to Auckland at FL340. The crew of OED also observed an indication of that aircraft on their TCAS.

The vertical separation standard was 1,000 ft. The vertical distance between OED and OEB reduced to 800 ft, and to 700 ft between OED and the third aircraft. There was an infringement of separation standards.

The crews of OEB and OED were communicating with Tahiti ATC via both Controller-Pilot Data Link Communications (CPDLC) and high frequency (HF) radio. CPDLC was a 'means of communications between a controller and pilot using data link for [Air Traffic Control] communication' (ICAO Doc 4444 ATM/501 14.1.1). Messages were compiled and initiated either by the crew of the aircraft or by ATC and were, in this case, pre-formatted. The use of pre-formatted messages was 'intended to reduce the possibility of misinterpretation and ambiguity' (ICAO Doc 4444 ATM/501 14.3.4).

The crew of OEB had requested climb from FL320 to FL340 but that request was denied. About ten minutes later the crew of OED requested climb from FL330 to FL350. Tahiti ATC asked the crew of OED, via CPDLC, when they could reach FL350 and then denied the request for climb. The French Bureau d'Enquetes et d' Analyses pour la Securite de l'Aviation Civile (BEA) produced a report on the occurrence. The BEA reported that the crew of OED then contacted Tahiti ATC via HF radio and advised that they could reach FL350 by time 1140 universal coordinated time. The controller responded via HF radio and instructed the crew of OED to maintain FL330. The crew of OEB then requested, via CPDLC, climb to FL330. The CPDLC response provided to the crew of OEB was 'climb to and maintain FL330 due to traffic' even though FL330 was not available. The message was selected by the controller from the menu of pre-formatted messages available in the system.

The South Pacific Operations Manual (SPOM Part 5.5) stated that 'when a clearance request is denied, the controller shall use the element "UNABLE" in the uplink message'. The SPOM detailed the procedures and requirements applicable in the South Pacific flight information regions (FIRs) for CPDLC equipped aircraft and applied within the Tahiti FIR. The SPOM (Part 5.1) also stated that `generally, when a CPDLC aircraft is operating within a CPDLC FIR, CPDLC will be the primary means of communication'.

Subsequent to the occurrence OEB returned to FL320 and OED returned to FL330. The crews then reported to Tahiti ATC at those respective levels. The controller had not intended to assign FL330 to the crew of OEB and did not realise that they had been assigned FL330, or that they had climbed to FL330 and subsequently returned to FL320. When the crews reported at FL330 and FL320 respectively, after the occurrence, that information was consistent with the information the controller had recorded on the flight progress strips. The controller was not aware that there had been an infringement of separation standards.

The BEA reported that the controller believed there were possibly two reasons why a climb instruction had unintentionally been assigned to the crew of OEB:

1. In reply to the request by OEB for climb to FL330, the controller pre-selected the wrong pre-formatted CPDLC message and sent the message without checking it, or

2. The controller confused the two aircraft because of their similar callsigns.

The BEA reported that four controllers had been rostered for the period between 1900 hours and 0700 hours (Papeete local time) and were rostered to cover the aerodrome control position, the approach control position and the area control position. The event occurred at 0050 Papeete local time. The controller involved in the occurrence was alone in the tower at the time of the occurrence and was performing all three functions. That controller considered that the workload was high due to poor quality HF radio, increased coordination with other centres in relation to aircraft using 'flexible routes' and difficulty validating CPDLC messages with OED.

The controllers at Tahiti had been trained in France but that training had not included the use of CPDLC. Initial training on the use of CPDLC was incorporated into a one-week training program in Papeete that included CPDLC with other local training requirements. Ongoing CPDLC training was incorporated into on-the-job training which could take controllers around 57 weeks to complete. Controllers reported that the initial training was essential but they had not been exposed to the system sufficiently during training to master all aspects of the system.

The controller involved in the occurrence had been working Tahiti Oceanic Controlled Airspace for approximately three and a half years and was qualified on the three ATC positions being managed at the time of the occurrence.

Occurrence summary

Investigation number 200200094
Occurrence date 31/01/2002
Location 111 km NNE PUMIS, (IFR)
State International
Report release date 23/01/2003
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Loss of separation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-OED
Serial number 25126
Sector Jet
Operation type Air Transport High Capacity
Departure point Auckland, NEW ZEALAND
Destination Los Angeles, U.S.A.
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-OEB
Serial number 25778
Sector Jet
Operation type Air Transport High Capacity
Departure point Los Angeles, U.S.A.
Destination Auckland, NEW ZEALAND
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration ZK-SUJ
Sector Jet
Operation type Air Transport High Capacity
Departure point Los Angeles, U.S.A.
Destination Auckland, NEW ZEALAND
Damage Nil

Disabling of the general cargo vessel ANL Purpose

Final report

Summary

At 2100 on Monday, 6 August, the small general cargo vessel ANL Purpose was at the position 18 23.6' S, 152 54.3' E making good 11 knots on a course of 174 (T) on passage from Lae, New Guinea, to Melbourne. The weather was fine. The nearest land was Marion Reef, 45 nautical miles to the southwest and Lihou Reef, some 76 nautical miles to the northwest. The master was on watch on the bridge and the chief engineer was in his cabin, when an engine alarm annunciated.

Upon investigating, the chief engineer heard loud noises coming from the main engine, which he promptly stopped. After opening the port crankcase door on no. 4 unit, he saw that both the piston and the cylinder liner had shattered into numerous small pieces and the engine sump was full of debris. There was also significant damage to the engine block. The chief engineer realised that it would not be possible for the ship's staff to carry out repairs sufficient to restart the main engine, even on five cylinders and, at 2215, he advised the Master accordingly.

The master informed the vessel's owner and AusSAR (the Australian Search and Rescue Co-ordination Centre) of the vessel's predicament. ANL Purpose was drifting, in a mainly north-westerly direction, at a speed of approximately 1.3 knots. It was, however, in no immediate danger.

At 1654 on 8 August, the Townsville-based tug Giru made a rendezvous with ANL Purpose which had, by that time, drifted to a position of 1759.1' S, 15215.1' E, and passed a tow to the ship. The tow, at a speed of 7 to 71/2knots, proceeded towards Brisbane in good weather with light south-easterly winds.

On 10 August, in the shelter of Saumarez Reef, the tow was taken over by the Brisbane-based tug Bulimba. The good weather held for the remainder of the tow to Brisbane and, on 12 August, ANL Purpose arrived at the repair wharf of Forgacs Cairncross shipyard in the Brisbane River.

The investigation concluded that:

  • The proximate cause of the failure was the partial seizure and consequent break-up of the piston in no. 4 unit. The partial seizure was brought on by an obstruction to piston cooling oil flow caused by the axial movement of the bottom-end bearing shells, which may have been incorrectly fitted.
  • The piston in no.4 unit was suffering from significant fatigue cracking, as were those in nos.1 and 2 units, and the additional loading from the partial seizure was sufficient to cause the break-up of the piston.
  • The pistons were those originally fitted sixteen years earlier and there was no evidence that they had ever been replaced or crack-detected during that time. The engine manufacturers had issued service bulletins relating to the maintenance and crack detecting of the later two-piece type of pistons, but not for the original, one-piece type.
  • The standard of maintenance records kept aboard the vessel was less than adequate.

The report recommends that the engine manufacturer consider issuing a service bulletin covering the crack-detecting of any of the earlier, one-piece, pistons which may still be in service.

Conclusions

  • The ANL Purpose main engine failure occurred due to the partial seizure and consequent fracture and break-up of the piston from the number-four cylinder assembly.
  • First indication of engine failure was the detection of elevated crankcase oil mist levels due to increased friction within the cylinder.
  • The presence of pre-existing fatigue cracking within the body of the number-four piston had contributed to the failure.
  • Two other pistons from the engine were also cracked in a similar manner.
  • In-service cracking of the pistons was a known design issue and the engine manufacturer had published enhanced inspection requirements for pistons that have accrued more that 24,000 operating hours. A later service letter published service time limits for the main components of the VASA 32 engines. At the time of the failure, the pistons from the ANL Purpose had a service time well in excess of the published limits for piston replacement.
  • The connecting rod big end bearing shells had migrated forward of their normal positions and had sustained damage as a result of contact with the crankshaft journal radius.
  • Movement of the bearing shells had partially obstructed the oil flow pathway between crankshaft and connecting rod / piston. At a constant feed pressure, this would reduce the total volume of oil flowing through the number-four assembly.
  • Control of the piston crown operating temperatures requires that a positive flow of oil be maintained. Any reduction of oil flow volume would be expected to result in an increase in piston temperatures.
  • An increase in piston temperatures will result in the physical expansion of the piston body, reducing the bore clearances and increasing the risk of binding and seizure. Evidence of binding and partial seizure was found on fragments of the piston skirt and cylinder bore from the failed engine, although it could not be ascertained at what stage of the failure the damage was sustained.
  • Binding within the cylinder bores will elevate the loads being transmitted through the piston body. Under these conditions, the presence of cracking or other defects may predispose the component to failure in the manner observed within the main engine of ANL Purpose.

Occurrence summary

Investigation number 170
Occurrence date 06/08/2001
Location Coral Sea
State International
Report release date 05/09/2003
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Marine
Marine occurrence category Engine Failure
Occurrence class Incident
Highest injury level None

Ship details

Name ANL Purpose
IMO number 8500070
Ship type General cargo
Flag Antigua and Barbuda
Departure point Lae, New Guinea
Destination Melbourne, Victoria

Boeing 737-376, VH-TAW

Safety Action

As a result of the occurrence, the airline operator issued a Flight Standing Order applicable to the Boeing 737 fleet. The following policy regarding taxi speed was stated:

"1. Maximum taxi speed on long straight smooth taxiways is 30 kts.

" 2. Maximum taxi speed entering a turn is 10 kts.

" 3. If the taxiway surface is other than dry crew judgement will dictate a lower speed."

Analysis

Although the act of taxiing an aircraft to and from an active runway may have become a routine task, ensuring that it was done safely required planning and constant vigilance by both members of the technical crew. In this particular instance, the aircraft was safely taxied a considerable distance in accordance with company procedures. However, as the aircraft approached the turn at taxiway "alpha", the crew was apparently unaware that the aircraft's speed was high. The aircraft entered the turn at an inappropriate speed and on a surface that was noticeably wet. The probability of maintaining directional control under those circumstances was doubtful.

It was considered likely that both pilots became accustomed to the relatively high taxi speed owing to the extended time spent on the long, straight taxiway that preceded the turn. The crew relied solely upon their visual estimation of speed in circumstances that required cross-reference to the EADI ground speed readout.

Although the taxiway treatment carried out by the airport operator resulted in a surface that was slippery, it was considered that the aircraft would have been unlikely to have left the taxiway if a speed appropriate for the existing conditions had been used.

Summary

A Boeing 737-376 aircraft was being taxied for a departure from runway 20 at Christchurch on a scheduled service to Auckland. The Automatic Terminal Information System indicated that the surface wind was from 200 degrees at 10-15 kts, the temperature was 6 degrees Celsius and the dewpoint was 5 degrees Celsius. The visibility was 10 km reducing to 3,000 metres in rain and drizzle. During the taxi, the crew observed that the weather was fine and that the taxiway was wet after recent rain.

The route to the threshold of runway 20 included a 1,600-metre straight section of the main taxiway which ran parallel to runway 02/20, and which had a slight downhill grade. Analysis of flight data recorder (FDR) data revealed that the aircraft was on that section of the main taxiway for 2.3 minutes and that the speed of the aircraft gradually increased from 11 kts until it reached a maximum of 29 kts. The operator's flight crew training manual (FCTM) contained the following information regarding taxi procedures:

"To the pilot, the airplane appears to be moving slower than it actually is due to the flight deck height above the ground. Consequently, the tendency is to taxi faster than desired.

"Taxi speed should be closely monitored during taxi out, particularly when the active runway is some distance from the departure gate.

"Avoid taxi speeds greater than 30 kt on long taxi routes.

"Allow for decreased braking effectiveness on slick surfaces."

Although it was not included in the most recent edition of the FCTM, previous text stated that when approaching a turn, the aircraft should be slowed to the appropriate speed for the conditions. On a dry surface, approximately 8 kt to 12 kt was recommended. The aircraft manufacturer inadvertently removed that maximum recommended cornering taxi speed, when the Boeing 737 FCTM was extensively rewritten.

At the end of the main taxiway, the route to the threshold of runway 20 required that the aircraft be steered to the left, through approximately 60 degrees, onto taxiway "alpha". The pilot in command began braking the aircraft before reaching that turn point, but the aircraft had only slowed to 25 kt when the turn was commenced.

During the turn the nosewheel started "scrubbing", indicating excessive steering angle and/or taxi speed for the surface condition. Lacking traction, the nosewheel moved sideways and directional control was lost. That was followed by loss of traction on the main gear. As the aircraft moved sideways, the right main gear slid off the paved surface and onto the grassed area adjacent to the taxiway. The aircraft came to a halt with the right main gear settled slightly in the soil.

A maintenance engineer attended the aircraft, assessed that there was no obvious damage and then marshalled the aircraft back onto the taxiway. The aircraft was then taxied back to the terminal where a detailed inspection of the landing gear, the brakes and the engines was carried out. That inspection did not reveal any damage and the aircraft was released back into service.

The technical crew of the Boeing 737 consisted of a pilot in command and a co-pilot; both of whom were very experienced on the aircraft type. The airline operator had only recently commenced operations from this airport; the crew's local experience was therefore limited. The Boeing 737 nose wheel steering system was only controllable from the left control seat. Therefore, the pilot in command always taxied the aircraft. Either pilot could have used the ground speed readout on the pilots' electronic attitude director indicator (EADI) to monitor the taxi speed. The airline's normal procedure was for the co-pilot to bring to the attention of the pilot in command, any unsafe speed. During the airline operator's subsequent investigation of the incident, both pilots expressed surprise at the high speed recorded by the FDR during the turn.

The taxiway in question was treated during February 2001 with a surface enrichment treatment that resulted in making the surface more slippery. A notice to airmen (Notam) was issued on 20 March 2001 that advised poor braking action was possible when the surface was wet. That Notam was subsequently cancelled on 27 May 2001, when it was considered that the taxiway surface had weathered sufficiently for friction levels to return to normal.

During August 2001, a different airline operator reported another two minor skid events at that same location. Neither of those incidents resulted in the aircraft leaving the sealed area. As a precautionary measure, the airport operator re-issued the Notam that warned of the possibility of poor braking action. The taxiway surface was subsequently roughened by water blasting. That action removed the smooth bitumen top layer and exposed the aggregate for a better friction surface.

Occurrence summary

Investigation number 200103240
Occurrence date 22/07/2001
Location Christchurch, Aero.
State International
Report release date 04/02/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 737
Registration VH-TAW
Serial number 23488
Sector Jet
Operation type Air Transport High Capacity
Departure point Christchurch, NZ
Destination Auckland, NZ
Damage Nil

Boeing 747-444, VH-NLH

Safety Action

Local safety action

As a result of the investigation, Airservices Australia reminded its Brisbane TOPS Group staff:

  1. to utilise staff appropriately to maintain safety and the integrity of the air traffic system, and
  2. to leave the operational room when not required for duty.

Brisbane Centre also reviewed refresher training with a view to incorporating controller defensive techniques.

Occurrence summary

Investigation number 200101996
Occurrence date 06/05/2001
Location GUTEV, (IFR)
State International
Report release date 11/02/2002
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-NLH
Sector Jet
Operation type Air Transport High Capacity
Departure point Sydney, NSW
Destination HONG KONG
Damage Nil

Aircraft details

Manufacturer The Boeing Company
Model 767
Registration ZK-NCL
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination HONG KONG
Damage Nil

Aerospatiale AS332L, VH-BHK

Summary

The Aerospatiale AS332L helicopter was tracking inbound to Darwin from the Timor Sea, in instrument meteorological conditions (IMC). The pilot-in-command was using the global positioning system (GPS) to track to the initial approach fix for a runway 11 VOR/DME approach.

The pilot reported that when air traffic control cleared the helicopter for the approach, he switched his navigation source control switch from A NAV (the selection for navigation using GPS) to NAV 2 and VOR 2 for the approach. Immediately, the navigation EMERG MODE light on the pilot's bearing pointer's control panel illuminated. In accordance with the emergency checklist, the pilot selected his radio navigation sources to ADF 1, VOR 2 and NAV 2.

After the helicopter had passed the initial approach fix and was established on the final approach leg, the pilot observed that the course bar on his horizontal situation indicator (HSI) was central but his NAV 2 bearing pointer indicated that the helicopter was between 5 and 10 degrees right of track. The pilot, who was occupying the right pilot seat, asked the co-pilot to check the instrument indications on the left side HSI. The course bar on the co-pilot's HSI was indicating half scale left of track and the co-pilot's bearing pointer was also showing that the helicopter was to the left of track.

At that point the helicopter descended into visual meteorological conditions (VMC) and the pilot discontinued the instrument approach. The pilot changed his navigation source switches to the same selections as the co-pilot's switches and the pilot's course bar and bearing needle both showed the helicopter to be left of track, which it was. No OFF flags appeared on either pilot's navigation instruments prior to making the change. The pilot landed the helicopter normally and by the time the helicopter arrived at its base, the fault was no longer evident.

Engineers were unable to reproduce the fault on the ground. Engineers later reported that illumination of an EMERG MODE light indicates one of three types of fault;

(a) a fault in the navigation signal being received by the aircraft;

(b) a fault in the navigation switching power supply; or

(c) an internal fault in the navigation switching system.

Although engineers could not be certain, they suspected an internal fault in the switching system, probably a sticking relay. This was indicated by the appearance of the fault when the pilot switched navigation sources from A.NAV to NAV.2 for the approach.

Occurrence summary

Investigation number 200101926
Occurrence date 17/04/2001
Location 22 km WNW Darwin, (VOR)
State International
Report release date 13/06/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Aerospatiale Industries
Model AS332
Registration VH-BHK
Serial number 2096
Sector Helicopter
Operation type Charter
Departure point Northern Endeavour (TIMOR SEA)
Destination Darwin NT
Damage Nil

Boeing 747-438, VH-OJN

Safety Action

The operator has issued an internal advisory memo to maintenance personnel highlighting the event and the relevant required procedures when torqueing the connectors.

Analysis

The operator's investigation reported that the number four engine left and right fuel manifold connector attachments had been under torqued. The torque values, when checked, were as little as 80 inch pounds of torque instead of the correct value of 500 inch pounds. The engine had been last overhauled in August 1997. The connectors were documented as being correctly torqued and lockwired at that time. The only other documented maintenance in the area was completed during scheduled maintenance in May 2000, when a leak at one of the fuel nozzles was corrected. The area of the connectors is accessed on a regular basis for routine inspections, borescope inspections, and igniter plug changes. It could not be established why the connectors were under torqued.

Summary

Shortly after take-off, the crew of the Boeing 747 aircraft received a number four engine fire warning advisory. The crew actioned the non-normal checklist, secured the number four engine, and discharged two engine fire bottles before the fire indication extinguished. The crew then jettisoned fuel and completed an uneventful landing at the departure airport.

Initial inspection by operator maintenance personnel revealed evidence of charring and discolouration around the engine combustion area. Maintenance personnel removed the engine from the aircraft and the engine was then test run on an engine test cell. The test run revealed a fuel leak from the left and right fuel manifold connectors. The connectors were confirmed as being secured with safety lockwire, but subsequent torque checks revealed a lower value of torque than that required by the engine manufacturer's maintenance manual. The fuel manifold connectors were re-torqued and another test run completed. The resulting test run at high power settings revealed no discrepancy. A decision was made by the operator to have the engine overhauled before being put back into service.

Occurrence summary

Investigation number 200100622
Occurrence date 15/02/2001
Location 15 km SW Bangkok, Aero.
State International
Report release date 27/07/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Fuel systems
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-OJN
Serial number 25315
Sector Jet
Operation type Air Transport High Capacity
Departure point Bangkok, THAILAND
Destination London, UK
Damage Nil

Boeing 747-438, VH-OJJ

Safety Action

The company issued an "Important Information" bulletin to flight attendants advising that any visible cabin light fitting must have a protective grill or glass covering the bulb.

Summary

At top of descent to Los Angeles, the cabin crew of the Boeing 747 aircraft reported smoke and fumes emanating from the cabin ceiling located in the vicinity of the rear right side (R5) emergency exit door. Smouldering paper tissues were found in an overhead light fitting. Cabin crew removed the tissues and discharged a fire extinguisher onto the light fitting, tissues, and surrounding area. The cabin crew remained in the vicinity and monitored the area until passengers disembarked at Los Angeles.

The company reported that the light fitting is a "night light" and is always "on". The light has a blue plastic cover that should always be in place, but was not fitted on this occasion.

The investigation was unable to determine why, or by whom, the tissues were placed in the light fitting.

Occurrence summary

Investigation number 200100741
Occurrence date 22/02/2001
Location 111 km E Los Angeles, Aero.
State International
Report release date 08/08/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Smoke
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 747
Registration VH-OJJ
Serial number 24974
Sector Jet
Operation type Air Transport High Capacity
Departure point New York, USA
Destination Los Angeles, USA
Damage Nil

Loading related Boeing 767-338ER, VH-OGU, Honolulu International Airport, on 21 January 2001

Safety Action

The B767 operator has since amended procedures for its agent at Honolulu. Under the new procedures, only the supervisor will carry out weight unit conversions and liaise with other operators' agents. This should minimise the risk of erroneous information being passed between agents and help to ensure that all required checks are carried out.

The B767 operator is monitoring the effectiveness of the new procedures.

Summary

During cruise, the Boeing 767 (B767) crew noticed that the fuel consumption was 230 kg per hour more than normal. After the cargo had been unloaded at the destination, the crew had the cargo re-weighed. The actual cargo weight was more than 3,400 kg greater than the weight stated on the manifest.

The operator reported that its investigation revealed that four pallets had been carried from Honolulu to Sydney and that all were heavier than the weights recorded on the manifest. The discrepancies were 2,277 kg, 887 kg, 220 kg, and 10 kg.

The two pallets with the greatest weight discrepancies had been transported from mainland USA in a freight aircraft operated by a US operator, and had been transferred at Honolulu to the B767 for onforwarding to Sydney. The weights stated on the pallet tags for the internal US leg were in pounds, but the B767 operator required the weights to be in kilograms. The agent who handled the freight for the US operator at Honolulu converted the weights from pounds to kilograms and pencilled in the converted weights on the deadload sheet for the Honolulu-to-Sydney flight.

When the agent who handled freight at Honolulu for the B767 operator received the pallet weights, she did not check the figures against the loadsheet issued by Load Control. Consequently, she did not realise that the weights stated on the loadsheet had already been converted to kilograms, and applied the conversion a second time. Also, as the agent for the US operator was confident that she had passed the correct weights to the B767 agent, she did not recheck to ensure that the B767 agent had received the correct weight information.

The 220 kg and 10 kg weight discrepancies affecting the other two pallets were probably the result of weighing or recording errors.

The B767 operator has since amended procedures for its agent at Honolulu. Under the new procedures, only the supervisor will carry out weight unit conversions and liaise with other operators' agents. This should minimise the risk of erroneous information being passed between agents and help to ensure that all required checks are carried out.

The B767 operator is monitoring the effectiveness of the new procedures.

Occurrence summary

Investigation number 200100596
Occurrence date 21/01/2001
Location Honolulu International Airport
State International
Report release date 06/06/2001
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Miscellaneous - Other
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer The Boeing Company
Model 767
Registration VH-OGU
Serial number 29118
Sector Jet
Operation type Air Transport High Capacity
Departure point Honolulu, USA
Destination Sydney, NSW
Damage Nil

Boeing 747-400, VH-OJT

Safety Action

Local safety action

The Honolulu Air Traffic Control Facility completed mandatory team briefings for all personnel on the circumstances of this occurrence. All operational personnel were briefed on maintaining awareness, scanning, and vectoring with increased emphasis placed on operational supervision.

Summary

A Boeing 747-400 was enroute from Los Angeles to Melbourne, cruising at FL320 in a south-westerly direction on airway R576 in the Oakland Flight Information Region. A McDonnell Douglas MD-11 departed Honolulu and was climbing in an easterly direction to FL350. The aircraft were on converging tracks.

The Honolulu Air Traffic Control Facility was responsible for providing positive separation between the aircraft. The radar separation standard was 5 NM lateral, or 1,000 ft vertical.

A controller subsequently recognised that, without intervention, the tracks of the two aircraft would come within 5 NM when less than the required vertical separation existed. The controller instructed the MD-11 crew to "...fly heading 020 ..." to change the aircraft's track. The crew responded by broadcasting "... Air 205, now right, right heading...". The controller did not clarify the required turn direction, and then instructed the B747 crew "...fly 180, vectors on traffic". Those instructions were passed 60 seconds and 49 seconds respectively, prior to the aircraft passing each other.

The B747 crew correctly read back the instruction to fly 180 degrees. Immediately after receiving that instruction, the crew received a traffic advisory alert from the aircraft's traffic alerting and collision avoidance system (TCAS). The alert was followed by a TCAS annunciation of a resolution advisory (RA) to descend. The crew advised air traffic control, "... heading 180 and TCAS descent", as they descended the aircraft, in accordance with standard operating procedures. The crew had the MD-11 in sight for the duration of the incident.

Analysis of the continuous data recording plot indicated that the MD-11 did not commence the left turn until after the aircraft had passed. There was no indication that the B747 turned onto a heading of 180 degrees. A minimum of 700 ft vertical separation existed when there was less than 5 NM between the aircraft. An infringement of separation standards had occurred.

The MD-11 crew apparently misunderstood the instruction to fly heading 020 as "right" heading 020 degrees. A right turn would have been confusing to the crew as the aircraft was tracking approximately 090 degrees. The direction of turn onto a new heading would normally be flown via the shortest arc distance; in this case, a turn onto a heading of 020 degrees would normally involve a left turn. Thirty-three seconds later the MD-11 crew sought confirmation that a left turn to heading 020 degrees was required.

The crew of the B747 may not have turned as instructed due to their response to the TCAS alert, and their visual observation of the conflicting traffic. It could not be established whether standard separation would have been achieved if one or both crews had turned their aircraft when instructed to do so.

There was no evidence that the controller applied the principle of separation assurance in the control of these aircraft. Rather, the controller had relied on aircraft performance to achieve separation.

Occurrence summary

Investigation number 200100135
Occurrence date 15/01/2001
Location 106 km NE Maui, (OGG), (VOR)
State International
Report release date 17/12/2001
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-OJT
Sector Jet
Operation type Air Transport High Capacity
Departure point Melbourne, VIC
Destination Honolulu, Hawaii
Damage Nil

Aircraft details

Manufacturer McDonnell Douglas Corp.
Model MD-11
Sector Jet
Departure point Honolulu, Hawaii
Destination Unknown
Damage Nil