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Foul Odor On-Board American Airlines Plane Makes Passengers Ill

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    Hull Breach in American Airlines Flight


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    What: American Airlines Boeing 757-200 from Miami,FL to Boston,MA
    Where: Miami
    When: Oct 26th 2010
    Who: 154 passengers and 6 crew
    Why: A half hour after takeoff, the plane developed rapid decompression at 31,000 feet requiring oxygen masks, an emergency descent and a return to Miami.

    Maintenance found a one by two foot hole in the hull.

    George’s Point of View

    Maintenance, Maintenance, Maintenance!

    Even with AD Directives issued, this was still missed. Was there telltale evidence prior to this event that could have prevented endangering 154 passengers and six crew?

    The hole in the hull is not unprecedented. Sixteen months prior to flight AA-1640, Southwest Airlines (SWA) flight 2294, (another Boeing suffering a hole in the hull in July 13, 2009), the FAA has already issued Airworthiness Directive 2010-01-09 mandating inspection requirements. At that time, they ascribed the hull failure to a design fault: Fuselage skin failure due to preexisting fatigue at a chemically milled step.

    It’s an easy enough thing to visualize-picture slightly squeezing an empty cola can, then blowing into it; and repeating the process, over and over. In a soda can, it would not take the 20 years this plane has been flying for the stressed areas to develop a crease, and eventually crack.

    Not that a soda can is expected to sustain the significant pressures at 10,000+ feet, nor does it have the design flaw of chemical milling, nor is its skin made of single and double bonded layers. If it were, one could theoretically presume and anticipate metal fatigue to occur at the weakest location–the edges of where the metal is double-bonded.

    In the Southwest Airlines event, it was observed that the progression of metal fatigue tends to be higher at the borders between chemically milled and non-chemically milled bays.

    The inspection requirements in SB 737-53A1301 require inspections to detect cracks in the vulnerable areas (the chem-mill step) to avoid sudden fracture and failure of the fuselage skin panels.

    Did this plane undergo “repetitive external non-destructive inspections to detect cracks in the fuselage skin“?

    Carriers out there, when there are directives which indicate potential problems, pay attention!

    If not for the stellar performance of this flight crew, this plane would have been a statistic.

    Thank you, John D King for sending the links.

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    Mishaps of the day

    Some events that happened today:

    • December 16, 2013, on JetBlue Flight 836#N661JB, the Airbus A320 arrived at the gate at JFK airport, New York, and the left wing struck the jet bridge. There was only minor damage and no injuries reported.
    • In Farmington NY on December 17, 2013, a Piper PA28#N43080 engine caught fire when the plane started up. The fire was extinguished, with unknown damage.
    • December 16, 2013, a Lancair/235#N15TG landing at John’s Island Charleston SC, when the nose gear collapsed. Minor damage was reported.
    • December 16, 2013, a Cessna/172 #N421ER was taxiing when the wing struck a light pole. The accident occurred in Wickenburg Arizona. Minor damage was reported.
    • December 16, 2013, an experimental plane, a Zenith 601#N581SL crashed in Leakey Texas under unknown conditions.
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    Helicopter Crash in Kenya Leaves 4 Injured

    A 12-seater helicopter crashed at the National Youth Service (NYS) engineering institute near Mathare, Nairobi, Kenya, on September 8th.

    The helicopter carrying 4 people was on routine patrol when it developed a mechanical problem.

    All 4 people suffered non-life threatening injuries in the crash.

    The injured were taken to hospital.

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    Azul Brazilian Airlines Flight Makes Emergency Landing due to Smoke On-Board

    Azul Brazilian Airlines flight AD-9277 made an emergency landing in Vitoria da Conquista, Brazil, on January 15th.

    The plane flying from Belo Horizonte, Brazil, was descending toward Vitoria da Conquista when the crew declared an emergency due to smoke on-board.

    The plane continued for a safe landing. All sixty-nine passengers and five crew members remained unharmed.

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    Flats Cause Diversion to JFK for Boston-Kansas Flight


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    What: Pinnacle Airlines Canadair CRJ-900 en route from Boston to Kansas City
    Where: JFK
    When: Aug 13th 2012
    Who: 73 passengers, 4 crew
    Why: On takeoff, both right main landing gears blew. Pilots diverted to JFK and made an emergency landing.

    After landing, the plane was stopped on the runway. A replacement jet was provided.

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