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How Kentucky UPS plane crash unfolded and what could have caused it

edited November 5 in Off-Topic
Following are edited excerpts from a current BBC report:

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The National Transportation Safety Board (NTSB) - which is investigating the crash - said they have recovered airport CCTV footage that shows the plane's left engine falling off from the wing during takeoff. The agency has also recovered the cockpit flight recorder and the flight data recorder, known as the black box, from the wreckage. The 38,000 gallons of fuel on board the MD-11 jet needed for the flight escalated the blaze, which quickly spread to several buildings beyond the runway and burned for hours.

Data from tracking website FlightRadar24 shows the plane began to taxi along the 17R runway at around 17:15 local time and managed to reach a top speed of 214mph. But verified footage shows that by the time the plane reached this speed a fire had completely engulfed its left wing and the aircraft struggled to climb away from the runway before the explosion.

The NTSB said the plane's engine was on fire as it was working to take off and then detached from the wing. The plane was able to climb to 175 ft and cleared a fence at the end of the runway before veering into buildings and businesses surrounding the airport. Analysts suggested that a dramatic failure of two of the engines may have been responsible for the disaster. The MD-11 transport plane uses three engines. Two are mounted under the wings, and a third is built into the tail at the base of the vertical stabilizer.

A senior lecturer in aviation operations said the footage appeared to show the third engine had been damaged because it expelled a burst of smoke. The damage could have happened while it was pelted with debris from the fire and the engine detaching: "The upper engine that expelled a puff of smoke appears to wind down almost immediately afterwards," he said. "That left only the right engine producing thrust, creating a severe power imbalance and leaving the aircraft unable to gain height. "Losing two engines during take-off leaves the aircraft with only a third of its power and little chance of maintaining flight, especially at maximum take-off weight.

Footage confirmed by BBC Verify showed a blaze engulfing the left wing of the plane, which then tilted to the left as it attempted to gain lift and take-off. Two experts independently suggested the left engine may have detached from the plane after suffering from a mechanical or structural failure. And the NTSB later confirmed that the left engine detached from the plane's wing during takeoff. A retired airline pilot and aviation safety expert told BBC Verify that it was "almost unheard of" for an engine to detach in flight. He also said the cargo plane would have been able to fly with just two engines but the damage caused by the fire on the left wing was likely so great it caused the plane's engine built into the tail to lose thrust.

Additional information: A report in The Guardian states that Flightradar24 said the plane had flown from Louisville to Baltimore earlier on Tuesday before returning to Louisville. That would seem to suggest that no significant maintenance work occurred immediately before the flight departure for Honolulu. That in turn suggests the possibility of an engine turbine blade failure, where the failed blade rips through the immediate area and causes additional damage to the engine and the surrounding area. Possibly that in turn caused damage debris to be sucked into the rear engine, completing the death sentence.

Additionally, the Wall Street Journal is reporting that the UPS cargo plane that crashed Tuesday was 34 years old and needed a critical repair on its fuel tank in September. The MD-11 plane was grounded in San Antonio from Sept. 3 through at least Oct. 18, according to flight records. Maintenance records with the Federal Aviation Administration show the jet needed a permanent repair to fix a crack in the fuel tank before it returned to service.

I have no idea if this would have any significance in this disaster, but if it turns out that the fuel tank repair was on the left wing, some serious questions will be asked.


Comment: This excellent BBC report is by far the most detailed explanation of the actual mechanical failure sequence that I've come across so far.




Comments

  • Thanks OJ. Just sad especially for those who lost their lives just doing their jobs.
  • Here's the latest on the MD-11 cargo fleet... excerpts from a current NPR report:
    LOUISVILLE, Ky. — UPS and FedEx will ground their fleets of McDonnell Douglas MD-11 planes "out of an abundance of caution" following a deadly crash at the UPS global aviation hub in Kentucky, the companies announced late Friday. The MD-11 aircrafts make up about 9% of of the UPS airline fleet and 4% of the FedEx fleet, according to the companies.

    FedEx said in an email that it will be grounding the aircrafts while it conducts "a thorough safety review based on the recommendation of the manufacturer." Boeing, which merged with McDonnell Douglas in 1997, did not immediately respond to an email from The Associated Press asking the reasoning behind the recommendation.

    The cargo plane was nearly airborne when a bell sounded in the cockpit, National Transportation Safety Board member Todd Inman said earlier Friday. For the next 25 seconds, the bell rang and the pilots tried to control the aircraft as it barely lifted off the runway, its left wing ablaze and missing an engine, and then plowed into the ground in a spectacular fireball.

    The cockpit voice recorder captured the bell, which sounded about 37 seconds after the crew called for takeoff thrust, Inman said. There are different types of alarms with varying meanings, he said, and investigators haven't determined why the bell rang, though they know the left wing was burning and the engine on that side had detached.

    Inman said it would be months before a transcript of the cockpit recording is made public as part of that investigation process. Jeff Guzzetti, a former federal crash investigator, said the bell likely was signaling the engine fire.

    "It occurred at a point in the takeoff where they were likely past their decision speed to abort the takeoff," Guzzetti told The Associated Press after Inman's news conference. "They were likely past their critical decision speed to remain on the runway and stop safely. … They'll need to thoroughly investigate the options the crew may or may not have had."

    Flight records suggest the McDonnell Douglas MD-11, built in 1991, underwent maintenance while it was on the ground in San Antonio for more than a month until mid-October. It is not clear what work was done.

    Comment:   "It is not clear what work was done."  That of course will be one of the most important and critical aspects of this tragedy.

  • edited November 8
    Tragic. The MD-11 (a later derivative of the DC-10) has been a real workhorse for the big shippers like UPS. Here, or elsewhere, it was noted that many have been converted to cargo from passenger service. You see a lot of them (UPS / FedX) at some major airports lined up one after another awaiting takeoff.

    It was a DC-10 that crashed just after departing O’Hare roughly 40 (?) years ago. The tail engine was a factor in that disaster. And ISTM another suffered hydraulic failure and was miraculously guided to a crash landing somewhere in the midwest by the crew (Oklahoma?) with many loss of life.

    Thanks OJ. Great article. Could well have been a passenger jet. My heart goes out to the crew. Would have been horrific. There are investment implications if - as suggested - FedX & UPS ground these for any length of time. Would certainly impact the economy. As an aside … the nation has become so obsessed with ”Trump this” / “Trump that” / “Shutdown chaos” that very newsworthy stories like the plane crash receive little attention.

    Not really needing to be said: Engines should not fall off planes. Should be an interesting investigation with hopefully some lessons learned that may make flying safer.
  • "The McDonnell Douglas MD-11 is a wide-body jet airliner that first flew in 1990 and was manufactured between 1988 and 2000..."

    Is this thing simply too old? Hairline cracks, wear and tear? Metal fatigue? At some point, used cars become more trouble than they are worth, too.
  • Thank you @Old_Joe for the article. Flew on DC-10 many times in the past.

    As I recall the plane that @hank mentioned underwent a catastrophic engine failure due to a crack pylon. If that is the case here, on ground inspection would detect the hairline / stress cracks during refueling assuming the cracks are visible. In addition, older planes undergo a complete inspection and load bearing parts are replaced based on number of flight hours being flew.
    https://simpleflying.com/how-engines-are-attached-to-aircraft/
  • edited November 8
    Thanks for sharing @Sven. Yes, your description of the O’Hare incident sounds about right.

    Thought I was an avid flyer until I met a gal on a recent flight who flies often due to her work and is also a very nervous flyer. She knew a lot more about planes than I do. And had even read up ahead of time on various flight perimeters, including NOAA’s predicted wind-sheer along the rout! Geez. That’s taking it to a new level.

    The DC-10? Hell of a plane. But everything I’ve seen says that the very similar L-1011 which came out around the same time and competed head to head with the DC-10 was a better quality plane. Problem was that it cost more to buy so never took off with the airlines.

    With the DC-10, as I recall, pilots actually flew the thing. Today so much more automaton
  • I was working in Elk Grove village Illinois, not far from that DC-10 catastrophe in 1979, when it occurred. The plane came down on the boundary of Elk Grove and DesPlaines. I recall that disaster well. It could have been a lot worse as that is a heavily populated area, with many homes.
  • Following is an excerpt from a report in The Columbian:
    LOUISVILLE, Ky. — Federal aviation officials issued an order Saturday for McDonnell Douglas MD-11 planes not to be flown pending further inspection, reinforcing cargo carriers’ decision to ground their fleets following a deadly crash at the UPS global aviation hub in Kentucky.

    UPS and FedEx said Friday that they were grounding their fleets of McDonnell Douglas MD-11s “out of an abundance of caution,” and the Federal Aviation Administration’s directive the following day sidelined the planes until inspection and correction of any problems. In the Louisville crash, the jet’s left engine detached during takeoff.

    “This condition could result in loss of continued safe flight and landing,” the FAA said.

    Comment: More typical FAA: A day late and many dollars short. It's pretty sad when the manufacturer and operators of an aircraft ground the plane before the FAA gets around to it.

    At least the FAA came to the conclusion that an engine falling off "could result in loss of continued safe flight and landing". I guess that's something.

  • omg. when you put it that way.....All the frikkin' Agencies are underfunded, anyhow. Uncle Orange Flea Brain has doubled-down, besides.
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