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Safer Skies - Uncontained Engine Failures. Orlando FSDO Corporate Seminar - August 2002. Ben Coleman, ASO-FSDO-15 Aviation Safety Program, Southern Region Flight Standards Service. Our special thanks to:. Mark Liptak & Ann Azevedo Engine & Propeller Standards Staff ANE-110 - PowerPoint PPT Presentation
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Safer Skies - Uncontained Safer Skies - Uncontained Engine FailuresEngine Failures
Orlando FSDO Corporate Seminar - August 2002
Ben Coleman, ASO-FSDO-15Aviation Safety Program,Southern RegionFlight Standards Service
Our special thanks to:Our special thanks to:
Mark Liptak & Ann Azevedo Engine & Propeller Standards Staff
ANE-110Engine & Propeller Directorate
FAA Aircraft Certification ServiceBurlington, Mass.
AgendaAgenda Safer Skies Background & Overview Commercial Fleet Growth Projections Engine Accident/Incident Information UEF Intervention Actions Summary
In the U.S. our focus is set by theIn the U.S. our focus is set by theWhite House Commission on White House Commission on
Aviation SafetyAviation Safety1.1 Government and industry
should establish a national goal to reduce the aviation fatal accident rate by a factor of five within ten years and conduct safety research to support that goal.
1.2 The FAA should develop standards for continuous safety improvement, and should target its regulatory resources based on performance against those standards
5.3-2
White House CommissionWhite House CommissionRecommendationsRecommendations
Five-Fold Accident Reduction
Partnership with NASA and the aviation industry
Develop and share safety data and analysis tools
The National Civil Aviation Review The National Civil Aviation Review Commission (NCARC) Commission (NCARC)
on Aviation Safety Provided Additional Directionon Aviation Safety Provided Additional Direction
• FAA and the aviation industry must develop a strategic plan to improve safety, with specific priorities based on objective, quantitative analysis of safety information and data. And….
5.3-3
The National Civil Aviation Review The National Civil Aviation Review Commission (NCARC) Commission (NCARC)
on Aviation Safety Provided Additional Directionon Aviation Safety Provided Additional Direction
• Government should expand on their programs to improve aviation safety in other parts of the world.
5.3-3
NCARC RecommendationsNCARC Recommendations80% REDUCTION IN THE COMMERCIAL FATAL
ACCIDENT RATE WITHIN 10 YEARS
FAA and industry prioritize safety agenda and implement a strategic plan
FAA safety programs must become performance based
Government/Industry partnership
Strengthen international activities
HUMAN FACTORSIN OPERATIONS &
MAINTENANCE
Carry-on Baggage
Child Restraint
Passenger Interference
CABIN SAFETY
IMPROVED DATA & ANALYSIS
GENERAL AVIATION
Loss of Control
Weather
Survivability
Pilot Decisionmaking
Controlled Flight Into Terrain
Approach and Landing
COMMERCIAL AVIATION
Controlled Flight Into Terrain
Loss of Control
Weather
Uncontained Engine Failures
Runway Incursion
Passenger Seat Belt Use
Runway Incursions
SAFER SKIES - A FOCUSED AGENDA
Hull Loss Accident Rates by World RegionsHull Loss Accident Rates by World Regionsby Accident Siteby Accident Site
Western-Built Transports, 1988 through 1997
United Statesand Canada
0.5
Latin Americaand Caribbean
4.7
Europe0.8
China2.7
Middle East1.9
Africa9.5
Asia2.3
World1.4
Oceania0.5
Accidents permillion departures
(ExcludingChina)
JAA - 0.6NonJAA - 1.2
C.I.S.*
*Insufficient data to generate reliable rate.
Potential for Totally New Airplane Designsto Affect Safety is Very Small
25,000
20,000
15,000
10,000
5,000
02005 2010 2015
Number ofairplanes Total Airplanes Produced
After 1998
2000
Out of Production Models(as of 1998)
Current Fleet
New Designs
1998 2007
CommitmentCommitmentPrevention of accidents is our
highest priority Resources for critical
interventions–Focus on top safety areas–Ensure full implementation
CornerstoneCornerstone
Commitment of resourcesStandardized, focused
approachPartnerships with aviation
community
What is uncontainment?
• Uncontainment is when internal engineparts have passed completely throughthe nacelle of the engine
• Also of interest are events that arecontained by the nacelle, but penetratethe engine containment case
Relevant Acronyms :Relevant Acronyms :Aerospace Industries
Association (AIA)Continued Airworthiness
Assessment Methodologies (CAAM)
CAAM Event DefinitionsCAAM Event Definitions
Level 4 (Severe Consequences):–Hull loss–Fatal or serious injury–Forced landing
CAAM Event DefinitionsCAAM Event Definitions Level 3 (Serious Consequences):
– Substantial damage to aircraft or unrelated system
– Uncontrolled fire– Rapid depressurization– Temporary or permanent inability to climb/fly 1000 ft above terrain– Temporary or permanent impairment of aircraft controllability
CAAM Event DefinitionsCAAM Event Definitions
Level 2 (Significant Consequences):
–Nicks, dents, minor damage–Controlled fire or slow depres–Minor Injuries–High-speed takeoff abort
CAAM Event DefinitionsCAAM Event Definitions
Level 1 (Minor Consequences):–Uncontained damage
confined to nacelle–Separation, uncommanded
power increase, no loss of control
Causal Factors of Disk FracturesAccident (level 4)
Hazardous events:~ 16 per 100 M flights
All non-contained:~ 32 per 100 M flights
low cyclefatigue
high cyclefatigue
manufact .defect
materialdefect
shopmaint . &overhaul
fretting/rubbing
erosion/corrosion
bearingfailure
overspeed overtemp FOD
ForgingMachiningPeening
TitaniumInconelSteelOther
Unapproved partAssembly errorInspectionRepair
BirdsA/C ice shedBlue iceBMOD
Loss of diskcooling,Limitationexceeded
Shaft failureFuel ControlClosed VSVs
Examples
Opportunity to Inspect
~ 5 per 100 Million Flights
Maintenance Program Part Fractures
Uncontained Engine Failure Uncontained Engine Failure Sioux City Sioux City (July 1989)(July 1989)
DC10-10 crashed on landing
Multiple inspection opportunities before failure
In-flight separation of stage 1 fan disk– Metallurgical processes
over-hardened material– 111 fatalities No. 2 engine stage 1 fan disk (reconstructed with blades).
Uncontained Engine Failure Uncontained Engine Failure Pensacola Pensacola (July 1996)(July 1996)
MD-88 engine failure on take-off roll
Multiple inspection opportunities before failure
Stage 1 fan disk separated; impacted cabin– Failure from abusively
machined bolt-hole– 2 fatalities
Visual Aid -Visual Aid -
Turbofan Engine Malfunction:
Recognition and Response
Disk fractures are the major propulsion system risk
Current rate of hazardous uncontained events is 0.9 every 10 million takeoffs.
Number of uncontained events expected to increase as commercial fleet grows
Considerable crack growth time precedes most disk fractures
Uncontained Engine FailuresUncontained Engine Failures
Prioritized the most safety significant parts and features, linked to the best inspection method
ADs to mandate enhanced inspections of selected safety critical parts/features – instructions in OEM manuals
Multiple waves of AD’s being issued - about 3/4 of commercial fleet affected
Target UEF reduction 40 to 50%
UEF Intervention ActionUEF Intervention Action
SummarySummary
• Data driven intervention actionsData driven intervention actions• Prioritized for max safety benefitPrioritized for max safety benefit• Cooperative effort between FAA and Cooperative effort between FAA and
industryindustry• AD’s to mandate focused inspection AD’s to mandate focused inspection of critical features on safety of critical features on safety
critical partscritical parts
SummarySummary
• fan and HPT AD’s issued -fan and HPT AD’s issued - high compressors and LPT’s being high compressors and LPT’s being worked worked • performance measurements in performance measurements in place place through 2007through 2007
Questions ??Questions ??Answers Answers
http://www.faa.gov/certification/aircraft/
engine_special_topics.htm
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