VI The AAIB Investigation/Racal
Report
A very detailed examination of the crash site
and the wreckage of the aircraft was carried out by Mr Cable of
the Air Accidents Investigation Branch of the Department of Transport.
He subsequently prepared a report, the main text of which extends
to 60 pages. He gave evidence during the inquiry over a period
in excess of four days and spoke of the content of his report.
This and his evidence speak for themselves and I do not think
that there would be any useful purpose in my rehearsing them at
length. I have incorporated some of the salient conclusions of
his report in the findings in fact, and rather than attempt to
summarise or paraphrase what else he had to say, I think that
it would be preferable simply to quote those parts of his report
which seem to me to have particular relevance to this inquiry
(and for the avoidance of doubt I accept as accurate what is said
in these excerpts). Mr Cable began his report with a summary which
was as follows:
"ZD576 impacted a hillside near the Mull
of Kintyre Lighthouse while in transit from Aldergrove to Inverness
with four crew and 25 passengers on board, There were no survivors.
My examination of the crash site and detailed wreckage inspection
and testing showed that the aircraft struck a rocky outcrop 810
feet amsl on the side of a 1,404 feet amsl hill while tracking
012ºT at around 150 knots groundspeed and climbing at approximately
20º. It was erect, banked slightly left and pitched around
30º nose up, probably with cockpit control demands of substantial
aft and left cyclic stick, left yaw and full thrust present. A
Boeing simulation indicated that a sharp up-collective and back-cyclic
pull-up manoeuvre combined with initial conditions of approximately
150 knots airspeed and 1,000 ft/min climb rate was required to
produce the assessed combination of aircraft pitch attitude, flight
path, speed and DASH and LCTA extensions at impact. Much of the
fuselage undersurface and rear end was torn off and the right
and lower area of the cockpit damaged. The aircraft then travelled
almost 200 metres airborne while sustaining fuselage strikes from
rotor blades and executing extreme violent manoeuvres. It impacted
the ground inverted and broke into two major pieces which tumbled
a short distance, shedding the aft pylon and both engines. Fuel
tanks on both sides ruptured at initial impact and extensive ground
fire initiated, severely damaging much of the remains.
The aircraft's completeness could not be positively
verified but no evidence was found to suggest pre-impact separation
of any part. Indications were found that both flight control hydraulic
systems had been pressurised; thorough assessment of most control
system components was possible and revealed no signs of pre-impact
failure or malfunction, although the possibilities of pre-impact
system jam or detachment of control pallet inserts were not positively
dismissible. Available evidence indicated normal AFCS operation.
The integrity of the aircraft's electrical generation system could
not be positively established, but a number of services had been
receiving power at impact; available evidence suggested that all
electrical power had been lost very soon afterwards. Barometric
altimeter subscale settings were probably at 989 and 991.5 mb.
Several defects in the radar altimeter system were identified
but had probably not severely degraded its performance and signs
suggested generally correct indication at impact; low level warning
cursors were at 850 feet and 69 feet, the selection of the audio
warning could not be established. Both powerplants were operating,
at similar, intermediate power levels that possibly reflected
aircraft manoeuvre effects, and the surviving No 1 (sic) DECU
monitoring system memory indicated that no anomalies had been
detected during the last flight and no unusual faults or exceedances
had been recorded over its life. No evidence of explosive effects
or pre-impact fire was found.
A detailed investigation of possibly relevant
technical aspects of the accident was made. The pre-impact serviceability
of the aircraft could not be positively verified but no evidence
was found of malfunction that could have contributed to the accident,
with the possible exception of a radar altimeter system fault".
In a summary of his findings in regard to the
aircraft's instrument. Mr Cable recorded that the course selectors
on the Horizontal Situation Indicators "were probably at
028º and 035º for left and right indicators respectively,
and the left indicator steer bar had probably been indicating
0.9 divisions left at the time of indicator deformation".
He went on to describe two faults in the radar altimeter system,
one of which would not have affected the performance of the system
below 800 feet. The other was a receiver fault of which Mr Cable
wrote: "The receiver fault, apparently predominantly the
result of incorrect adjustment and positively present before the
accident had the potential for causing incorrect height indication
due to false lock-on, but a previous flight test result indicated
that this was unlikely, provided the antenna environment for ZD576
was similar to that for the test. In circumstances where the terrain
closure rate exceeded the system's track rate limit of approximately
90 ft/sec the fault also was likely to have increased somewhat
the maximum over-reading indication error that would have built-up
before lock was lost and re-acquisition occurred, probably to
approximately 80 feet".
In a summary of his findings in regard to the
aircraft's flight control system Mr Cable recorded that: "Almost
all parts of the mechanical systems for each of the four channels
were identified, with no evidence of pre-impact failure or malfunction,
although the possibility of control system jam could not be positively
dismissed. The collective balance spring bracket that had previously
detached from ZD576's thrust/yaw control pallet had detached,
but so had most of the similar inserts and the method of attaching
components to the pallets appeared less positive and more difficult
to verify that would normally be expected for a flight control
system application, and little evidence was available to eliminate
the possibility of pre-impact detachment of any of the pallet
components."
The reference in this last passage to the collective
balance spring bracket having previously detached from the thrust/yaw
control pallet was a reference to an incident which had occurred
on ZD576 on 10 May 1994. On the RAF message form about this incident
it was recorded that whilst returning to RAF Odiham for a rotors
running crew change the pilot had noticed that the collective
movement seemed heavier than normal. The aircraft had been landed
at Odiham. In consultation with the oncoming captain a further
hover check had been made. The collective forces had proved unacceptable
and the aircraft had been closed down and engineering advice sought.
On investigation it had transpired that there had been a failure
of the bonding of inserts into the pallet to which the bracket
had been attached with the result that it had detached from the
pallet. At the end of the form there was a note as follows: "Emphasise
that whilst symptom is stiff collective control the main flight
safety concern is the danger of a loose article within the flying
control closet". There was also an indication that the cause
of the detachment was "to be determined following technical
investigation by Boeing Helicopters". Following the incident
an instruction was recorded in the Supplementary Flight Servicing
Register of ZD576 to the effect that during a before flight service
of the aircraft the security to its attachment point of the collective
balance spring bracket should be checked.
A similar incident appears to have occurred
in another Chinook MkII helicopter on 20 July 1995. The incident
signal relating to this incident recorded that the aircraft had
been landed for hook checks and that as control was passed from
a student pilot to the captain a slight "kick" was felt
in the cyclic pitch. On taking control the captain found that
the cyclic would not remain in the neutral trimmed position unless
physically held there. If pressure on the cyclic was relaxed it
moved forward in excess of two inches and had to be pulled back
against moderate pressure. The soundproofing was removed from
the control closet and it was observed that the mounting bracket
for the pitch balance spring had detached from the closet wall.
The aircraft was closed down and engineering assistance was sought.
It was ascertained that the cause of the incident was that moulded
inserts from the pitch balance spring mounting bracket had debonded
from the pitch and roll control pallet. The signal ended with
some comments by the Station Commander at RAF Odiham as follows:
"Previous incidents involving debonding mounts occurred last
year but as yet I have not seen results of the investigation.
It may be that we should be concerned over production and/or assembly
of these panels using inserts for which we do not seem to have
a reliable inspection technique".
For the sake of completeness it should be recorded
that K was asked some questions about the earlier of these two
incidents as follows: "Q.The first point I want to
ascertain is that at the foot of the page where the note is that
"Emphasise that whilst symptom is stiff collective control
the main flight safety concern is the danger of a loose article
within the flying control closet" and I think we saw elsewhere
that this was a matter which had been referred to Boeing? A.Yes.
Q.And we also know that following this the visual check
was instituted? A.Yes. Q.Are you aware that in December
of 1994 the Boeing response was that it did not in fact constitute
a hazard to flight safety and that the visual check need no longer
be carried out? A.No, I did not. Q.I think perhaps
the initial view that was taken was that there might be a risk
of perhaps a spring becoming detached and falling down and impeding
controls. Does that seem fair? A.Or any other part of the
assembly had become detached, yes. Q.And if it is discovered
that in fact the way that these items were fitted together that
that was not likely to happen, you are not really in a position
to help us with that? A.No." But no evidence was led
at the inquiry to substantiate the suggestions which were put
to K in this context. Mr Cable was asked about the possible effect
of a detachment from one or other of the pallets in the control
closet and said: "A.Detachment that had caused a severe
flight control difficulty I don't believe would be consistent
with the evidence I received from the site and wreckage examination
and the way in which the aircraft approached the initial impact
basically. Q.Can you elaborate on that? If I understand
what you are saying, the evidence available to you suggested a
certain flight to the point of impact and do you say that that
is not the flight you would have expected had there been a detachment
in this area or not? A.Yes, I think that is one aspect.
I mean, the other is that there were ear witnesses in the area
who have not reported any of the sort of fluctuations I would
have expected to be reported if the aircraft was in any flight
control difficulties and thereby excluding some dramatic manoeuvre
at some period before initial impact. I understand there is other
evidence from examination of the navigation equipment on the aircraft
that again does not suggest flight control system problems."
H was also asked about the matter as follows: "Q.Now,
can I ask you to give the court your view of the likelihood in
the first instance of there being a simultaneous or near simultaneous
complete loss of control of both pitch and control channels? A.Yes,
this would be something we looked at extremely carefully using
the evidence of both the AAIB Investigation and the history of
the aircraft in terms of possible loose articles and also in consultation
with the engineers at Odiham in terms of the possibilities of
such an occurrence and it is my belief that the possibility of
a single control jam is highly unlikely. The possibility of a
dual roll and pitch at the same time is even less likely".
Among the many items examined by Mr Cable were
the aircraft's Differential Air Speed Hold and Longitudinal Cyclic
Trim actuators. Of these he reported: "It was clear that
the DASH extensions found did not correspond to a high speed level
flight condition whereas the LCTA extensions did, and it appeared
possible that the settings could reflect a dynamic aircraft manoeuvring
situation at the point of impact. A study was therefore undertaken
to assess the consistency of the settings and to define the possible
manoeuvre . . . A Boeing study attempted to define the manoeuvre
necessary to produce the initial impact conditions that had been
derived from the technical investigation. The response of the
aircraft to a series of postulated control inputs was predicted
by mathematical modelling simulating the Chinook HC2's behaviour,
from a range of initial steady flight conditions. For each case
a predicted time history of flight path, airspeed, attitude and
DASH and LCTA extension conditions resulting from combinations
of large collective thrust and aft cyclic stick control inputs
was produced and assessed for a simultaneous match of the parameters
with ZD576's initial impact conditions. In some cases control
inputs were modulated during the manoeuvre. Sample results of
Boeings' assessment of a wide range of possible starting conditions
and control inputs are given in Ref 19. This showed that close
simultaneous matching of the predicted conditions with the criteria
was possible in only a few cases, and was very difficult or impossible
in all cases with an initial airspeed of 135 knots and below and/or
an initial climb rate of 500 ft/min and below. A ready match was
found where initial conditions combined an airspeed of 150 knots
and a climb rate of 1,000 ft/min and large collective and aft
cyclic control inputs were postulated. The results in the case
(Ref 19, Case 12) providing the best correlation, which occurred
2.9 seconds after the initiation of the manoeuvre, included:
| Initial Steady Conditions:
| |
| | Aircraft Weight
| 37,700 lb |
| | Aircraft CG
| Station 325 |
| | Density Altitude
| 420 ft |
| | Wind
| 24 Kt Tailwind Component |
| | Airspeed
| 150 kt |
| | Climb Rate
| 1,000 ft/min |
| Control Inputs (increment from trimmed position)
|
| | Collective
| 2.3 inch up |
| | Longitudinal Cyclic
| 2.6 inch aft |
| Conditions 2.9 seconds after control input
| |
| | Airspeed
| 135 kt |
| | Normal Acceleration
| 2.2 g |
| | Rotor Speed
| 204 rpm (91 per cent) |
| | DASH Extension
| 23 per cent |
| | LCTA Extension
| Virtually Fully Extended |
| | Aircraft Pitch Attitude
| 31º Nose Up |
| | Aircraft Roll Attitude
| 5º Left |
| | Aircraft Yaw Attitude
| 1º Left |
| | Flight Path Angle
| 20º above the Horizontal |
| | Climb Rate
| 4,670 ft/min |
| | Horizontal Distance Travelled
| 822 ft (250 m) |
| | Vertical Distance Travelled
| 128 ft |
| | Ground Speed
| 158 kt |
In layman's terms what this simulation demonstrated was that,
in order to have created the conditions found by Mr Cable in the
course of his examination of the wreckage of the aircraft and
the site of its initial impact, the aircraft would have had to
have been climbing at 150 knots airspeed and at a rate of 1,000
feet per minute when the control inputs postulated were made 2.9
seconds before the initial impact. And the result of these control
inputs was to bring about a cyclic flare over a distance of 812
feet during which the aircraft's nose pitched up to 31º from
the horizontal, its angle of climb increased to 20º above
the horizontal, it gained 120 feet in height and its airspeed
dropped from 150 to 135 knots.
Mr Cable also spoke to a very detailed report prepared by
Racal Avionics Limited on the aircraft's SuperTANS navigation
system. This was recovered from the wreckage and the contents
of its memory extracted for analysis of relevant data. Again,
I do not think that it is necessary to rehearse everything that
emerged from the analysis. But a number of points are worthy of
mention. The GPS and Doppler positions recorded at powerdown were
respectively about 200 metres to the south-west and to the south-east
of the aircraft's initial impact point. The report narrates (paragraph
2.4.3.5): "The accuracy of a Doppler maintained position
is very dependent on a good heading source. During manoeuvres
when the heading changes, this will usually induce errors in a
Doppler derived position, often due to the lag in the compass,
but also due to latency associated with differences in the times
at which all the many contributing parameters are input to the
Navigation computer. The accuracy of the Doppler position over
the flight suggests that there had been little change of heading
throughout the flight". The calculated times at power off
were 1659:10.4 GMT and 1659:36.0 UTC, in each case plus or minus
half a second. The difference between the two was accounted for
by the fact that the initial setting of GMT would have been entered
by the crew of ZD576. The SuperTANS had been selected to GPS and
the display at the time of power loss was as follows:
`^Tac:B'
`< < 025ºM'
`Dis:86.7Nm'
`vTTG:32.0'
This indicated that the SuperTANS was being operated in the
"Tactical Steer" mode and that a waypoint B would have
been selected manually by the crew. The course to steer to the
waypoint was 025oM and the two chevrons indicated that the aircraft
should turn left between 10o and 15o to make good the required
heading. The distance to the waypoint was 86.7 nautical miles
with an estimated time to go of 32 minutes given the current airspeed
of the aircraft and wind conditions. There was provision for the
operation of a steer meter on the Attitude Indicators on the aircraft's
instrument panels. The drive to the steer meter indicated a command
to make a track change to the left by 14o but it is not known
if this signal was being directed to the Attitude Indicators.
The aircraft's true heading corrected for magnetic variation was
034.4oT, the true airspeed 127.6 knots, the system wind 30 knots
from 170o, the system groundspeed 151 knots, the system track
026oT and the system drift west 8o. The baro-compensated altitude
at power down was 665 plus or minus 50 feet. This did not coincide
with the initial impact height of 810 feet. But it appears that
the error may have been attributable to pressure changes at the
time of the crash. The baro-compensated altitude 15 to 18 seconds
before power down was 468 plus or minus 50 feet. There was no
information within the SuperTANS on the aircraft's rate of climb.
Five waypoints had been entered into the SuperTANS as follows:
| Name | Latitude
| Longitude | Variation
|
| H | N 54º47.70
| W006º36.00 | W 8.0º
|
| A | N 55º18.50
| W005º48.00 | W 7.5º
|
| B | N 56º43.00
| W005º14.00 | W 7.5º
|
| C | N 57º35.02
| W004º04.45 | W 7.5º
|
| D | N 57º32.42
| W004º02.92 | W 7.0º
|
Waypoint A was evidently intended to be the Mull of Kintyre
lighthouse. The latitude and longitude entered into the SuperTANS
for the position of the lighthouse placed it 280 metres to the
south east of its true position. The selection to waypoint B was
made when the aircraft was about 0.81nm from the position entered
for waypoint A on a bearing of 018ºT. At that point in time
the aircraft was about 0.95nm from the position at power down
on a bearing of 022ºT. No time is recorded when the change
to select waypoint B was made.
|