航空 发表于 2010-8-24 12:45:03

Investigation Report Serious Incident Airbus Industrie / A320-200

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Identification<BR>Kind of occurrence: Serious Incident<BR>Date: 20. March 2001<BR>Location: Frankfurt / Main<BR>Type of aircraft: Transport category aeroplane<BR>Manufacturer / Model: Airbus Industrie / A 320-200<BR>Injuries to persons: no Injuries<BR>Damage to aircraft: A/C not damaged<BR>Other damage: none<BR>Source of Information: BFU Investigation<BR>Bundesstelle für<BR>Flugunfalluntersuchung<BR>German Federal Bureau of<BR>Aircraft Accidents Investigation<BR>Investigation Report 5X004-0/01<BR>April 2003<BR>mail: box@bfu-web.de<BR>http:// www.bfu-web.de<BR>Tel: +49 531 35 48 0<BR>Fax: +49 531 35 48 246<BR>Editor/Distribution:<BR>Bundesstelle für<BR>Flugunfalluntersuchung<BR>Hermann-Blenk-Str. 16<BR>38108 Braunschweig<BR>Identification<BR>Kind of occurrence: Serious Incident<BR>Date: 20. March 2001<BR>Location: Frankfurt / Main<BR>Type of aircraft: Transport category aeroplane<BR>Manufacturer/ Model: Airbus Industrie / A 320-200<BR>Injuries to persons: no Injuries<BR>Damage to aircraft: A/C not damaged<BR>Other damage: none<BR>Source of Information: BFU Investigation<BR>The investigation has been conducted in compliance with the Law relating to the Investigation<BR>into Accidents and Incidents Associated with the Operation of Civil Aircraft (Flugunfall-<BR>Untersuchungsgesetz - FlUUG) dated 26. August 1998.<BR>According to the Law, the sole objective of the investigation shall be the prevention of future<BR>accidents and incidents. It is not the purpose of this activity to apportion blame or liability or<BR>to establish claims.<BR>Investigation Report 5X004-0/01<BR>April 2003<BR>Bundesstelle für<BR>Flugunfalluntersuchung<BR>German Federal Bureau of<BR>Aircraft Accidents Investigation<BR>mail: box@bfu-web.de<BR>http:// www.bfu-web.de<BR>Tel: +49 531 35 48 0<BR>Fax: +49 531 35 48 246<BR>Editor/Distribution:<BR>Bundesstelle für<BR>Flugunfalluntersuchung<BR>Hermann-Blenk-Str. 16<BR>38108 Braunschweig<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 I<BR>Table of contents<BR>Abbreviations .................................................................................................................................. 3<BR>Synopsis ......................................................................................................................................... 4<BR>1. Factual information................................................................................................................. 6<BR>1.1 History of the flight .................................................................................................................... 6<BR>1.2 Injuries to persons..................................................................................................................... 7<BR>1.3 Damage to aircraft .................................................................................................................... 7<BR>1.4 Other Damage......................................................................................................................... 7<BR>1.5 Personnel information ............................................................................................................... 7<BR>1.5.1 Crew....................................................................................................................................... 7<BR>1.5.2 Technical Personnel................................................................................................................... 8<BR>1.6 Aircraft information.................................................................................................................... 9<BR>1.7 Meteorological information....................................................................................................... 16<BR>1.8 Aids to navigation ................................................................................................................... 16<BR>1.9 Communications ..................................................................................................................... 16<BR>1.10 Aerodrome information............................................................................................................ 16<BR>1.11 Flight recorder ........................................................................................................................ 16<BR>1.12 Wreckage and impact information ............................................................................................ 17<BR>1.13 Medical and pathological information........................................................................................ 17<BR>1.14 Fire....................................................................................................................................... 17<BR>1.15 Survival aspects ..................................................................................................................... 17<BR>1.16 Tests and research ................................................................................................................. 18<BR>1.17 Organizational and management information............................................................................ 18<BR>1.17.1 Operator................................................................................................................................ 18<BR>1.17.2 Maintenance Organisation....................................................................................................... 18<BR>1.17.3 Supervision of the maintenance organisation by the Luftfahrt-Bundesamt ................................... 19<BR>1.18 Additional information.............................................................................................................. 19<BR>1.18.1Documentation....................................................................................................................... 19<BR>1.19 Useful or effective investigation techniques............................................................................... 21<BR>2. Analysis ............................................................................................................................... 21<BR>2.1 Operator................................................................................................................................ 21<BR>2.2 Maintenance Organisation....................................................................................................... 22<BR>2.3 Documentation ....................................................................................................................... 25<BR>2.4 Supervision by the LBA ........................................................................................................... 25<BR>2.5 Illustration of the causal chain.................................................................................................. 26<BR>3. Conclusions......................................................................................................................... 27<BR>3.1 Findings ................................................................................................................................ 27<BR>3.2 Causes ................................................................................................................................. 29<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 II<BR>4. Safety Recommendations..................................................................................................... 30<BR>4.1 Immediate Actions .................................................................................................................. 30<BR>4.2 Actions during the investigation................................................................................................ 30<BR>4.2.1 Internal actions by the maintenance organisation ....................................................................... 30<BR>4.3 Safety recommendations following the completion of the investigation........................................ 31<BR>5. Enclosures:.......................................................................................................................... 31<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 3<BR>Abbreviations<BR>AMM Aircraft Maintenance Manual<BR>AOC Air Operator’s Certificate<BR>AWL Aircraft Wiring List<BR>AWM Aircraft Wiring Manual<BR>BFU Bundesstelle für Flugunfalluntersuchung<BR>BMVBW Bundesministerium für Verkehr, Bau- und Wohnungswesen<BR>(Federal Ministry of Transport, Building and Housing)<BR>CVR Cockpit Voice Recorder<BR>ECAM Electronic Centralized Aircraft Monitoring<BR>EFCS Electronic Flight Control System<BR>ELAC Elevator Aileron Computer<BR>FAC Flight Augmentation Computer<BR>FZE Flugzeugelektroniker (Aircraft Electronic Technician)<BR>GLB Ground Log Book<BR>JAA Joint Aviation Authorities<BR>JAR Joint Aviation Requirements<BR>LBA Luftfahrt-Bundesamt (Federal Office of Civil Aeronautics)<BR>MEL Minimum Equipment List<BR>QM Qualit&auml;tsmanagement (Quality Management)<BR>QMH Qualit&auml;tsmanagementhandbuch (Quality Management Handbook)<BR>QS Qualit&auml;tssystem (Quality System)<BR>ROD Reliability-Data on Demand<BR>SB Service Bulletin<BR>SEC Spoiler-Elevator Computer<BR>SfB Sammelblatt für Beanstandungen (list of complaints)<BR>SPM Standard Practices Manual<BR>SSFDR Solid State Flight Data Recorder<BR>TLB Technical Log Book<BR>UTC Universal Time Coordinated<BR>VA Verfahrensanweisung (Procedural Instruction)<BR>WD Wiring Diagram<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 4<BR>Synopsis<BR>On 21 March 2001 at 18:10 hrs1, the Federal Bureau of Aircraft Accidents Investigation (hereafter<BR>referred to as BFU) was informed of a serious incident at Frankfurt/Main airport.<BR>An Airbus A 320 had departed at 11:00 hrs UTC from runway 18 for a flight to Paris. 115 passengers and<BR>6 crew members were aboard the aeroplane. Immediately following the lift-off the aeroplane assumed a<BR>slight bank angle to the left. The commander, who was the pilot flying, tried to correct the attitude by a<BR>slight input on the left sidestick. However, the bank angle increased continuously up to approx. 22°. With<BR>the commander’s call out :“I can’t do anything more“ the first officer took over the controls with the words<BR>“I have control“ and pressed the TAKE OVER PUSH BUTTON. The First Officer had already beforehand<BR>instinctively tried to counteract the rolling movement with his sidestick.<BR>Controlled by the second autopilot the aeroplane climbed to flight level FL 120 where the crew cautiously<BR>analysed the control system. With an input on the left sidestick the aeroplane - after a short shaking and a<BR>brief bank angle corresponding to the input - suddenly reacted contrary. The right-hand sidestick<BR>functioned normally.<BR>The crew decided to not continue the flight but to return to Frankfurt. The First Officer took over the<BR>controls and safely landed the aeroplane in Frankfurt. The aeroplane was than handed over to the<BR>maintenance organisation.<BR>Prior to this flight, the aeroplane had already been at the maintenance organisation for two days for repair<BR>purposes. On several previously conducted flights had problems occured on one of the two elevator<BR>aileron computers (ELAC), which control, among other things, the bank angle. When the computer was<BR>replaced, a bent pin, which could not be repaired, was found on the plug of the ELAC no. 1. Therefore the<BR>whole plug of the ELAC no. 1 was replaced and rewired. Two pairs of wires were connected inverted, the<BR>Command Channel and the Monitor Channel.<BR>The BFU has come to the conclusion that the serious incident is due to the fact that:<BR>• during repair work on the plug of the Elevator Aileron Computer (ELAC) no. 1 two pairs of<BR>wires had been connected inverted<BR>• the error remained undetected<BR>• the error was not recognized by the flight crew during the “FLIGHT CONTROL CHECK“.<BR>Contributing factors were:<BR>• an unclear and difficult to handle documentation so that a wrong wiring diagram was<BR>used<BR>• diversion from the manufacturer’s data by the Maintenance Support<BR>1 Unless otherwise specified, all times are indicated in local time.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 5<BR>• manufacturer’s instructions which are not formulated unambiguously<BR>• functional check by the cross checking staff member was carried out incorrectly<BR>• iinsufficient functioning of the quality assurance<BR>• the lack of supervision of the maintenance organisation by the operator<BR>• a quantitatively and qualitatively insufficient supervision of the maintenance organisation<BR>and the operator by the supervising authority.<BR>• deficiencies in the “AFTER START CHECKLIST“ for the conduct of the “FLIGHT<BR>CONTROL CHECK“.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 6<BR>1. Factual information<BR>1.1 History of the flight<BR>In Frankfurt the crew performed a scheduled aircraft change. For the crew it was already the third<BR>flight whereas the aeroplane was to be used for the first time that day following repair work.<BR>Approx. 50 minutes prior to departure the crew was at the aeroplane. In the “TECHNICAL<BR>LOGBOOK“ (TLB) all complaints entered had been checked off as settled. The aeroplane had<BR>been released for the flight in accordance with the regulations by a “RELEASE TO SERVICE“.<BR>The preparations for the flight were completed on time. After the power plants had been started,<BR>prior to taxiing to runway 18, the “FLIGHT CONTROL CHECK“ was conducted by means of the<BR>“AFTER START CHECKLIST“. According to the statements of the crew, this check was accomplished<BR>pursuant to the valid procedures. During the check no irrecularities were found.<BR>The aeroplane taxied via taxiway “N-South“ to the take-off position of runway 18. During the takeoff<BR>run no abnormalities were found. During rotation the pilot-in-command noticed an increasing<BR>bank angle to the left. He tried to correct the bank angle through an opposite input on the left<BR>sidestick, but it grew increasingly larger.<BR>The First Officer reported that he instinctively made an input to the right on his sidestick, which prevented<BR>the bank angle from increasing even further, but did not lead to an improvement of the<BR>situation. Only after he had pressed the “TAKE OVER PUSH BUTTON“ on his sidestick, he regained<BR>full control of the aeroplane and was in a position to restore the normal flight attitude. He<BR>switched on the autopilot no. 2 and had the aeroplane climb to flight level 120. At FL 120, the crew<BR>cautiously checked the behaviour of the aeroplane control system.<BR>The autopilot no. 2 was switched off and the First Officer checked the aeroplane control system<BR>with the right-hand sidestick. The aeroplane reaction was in accordance with the control inputs.<BR>Afterwards the pilot-in-command took over the control. He slowly moved the sidestick to one side<BR>and after a short shaking movement the aeroplane unexpectedly moved to the opposite side. When<BR>it had become clear that the aeroplane reaction to control inputs on the left-hand sidestick was opposite<BR>to the inputs, the flight was discontinued. The First Officer landed the aeroplane safely on<BR>Frankfurt/Main airport.<BR>After the delivery of the aeroplane to the maintenance organisation a FLIGHT CONTROL CHECK<BR>was carried out in the presence of the crew, during which the symbols of the ailerons on the ECAM<BR>monitor first and for a very short moment moved into the corresponding direction, as if everything<BR>were alright, before the ailerons moved into the opposite direction.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 7<BR>1.2 Injuries to persons<BR>There were no injuries to persons.<BR>1.3 Damage to aircraft<BR>There was no damage to the aircraft.<BR>1.4 Other Damage<BR>There was no other damage.<BR>1.5 Personnel information<BR>1.5.1 Crew<BR>Pilot-in-command: 41 years/male<BR>Licences: Airline Transport Pilot Licence (ATPL)<BR>Ratings: - as a pilot-in-command of single piston engined<BR>landplanes up to 2000 kg maximum take-off mass<BR>- Instrument rating<BR>- as a pilot-in-command of A 319; A 320; A 321<BR>- long-range flight rating<BR>- aerobatics rating<BR>aeromedical examination: fit, without restrictions<BR>Flight experience: approx. 9 300 hours of which approx. 3 300 hours on<BR>A 320<BR>Rest period prior to the flight: approx. 20 hours<BR>Time on duty prior to the occurrence: approx. 06:30 hours<BR>Co-pilot: 27 years/male<BR>Licences: Airline Transport Pilot Licence (ATPL)<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 8<BR>Ratings: - as a pilot-in-command of single piston engined<BR>landplanes up to 2 000 kg maximum take-off mass<BR>- Instrument rating<BR>- as a first officer on A 319; A 320; A 321<BR>aeromedical examination: fit, without restrictions<BR>Flight experience: approx. 2 000 hours of which approx. 1 500 hours on<BR>A 320.<BR>Rest period prior to the flight: approx. 20 hours<BR>Time on duty prior to the occurrence: approx. 06:30 hours<BR>1.5.2 Technical Personnel<BR>A total of 6 staff members of the maintenance organisation were involved in the repair of the aeroplane.<BR>Aircraft mechanic 53 years/male<BR>employed by the organisation since: 1966<BR>A 320 qualification in accordance with JAR 145 Authorisations and LBA approved internal QM<BR>guidelines – Signing for Work Performance / FZE / B2 Airbus /A 320 / all ATA mechanical, Performance<BR>of Special Maintenance Processes / Duplicate Inspections (B2) / “Duplicate Inspection<BR>following Engine / Flight Control Changes“ / Airbus A 320 (IAE V 2500 and. CFM 56)<BR>Aircraft electronic technician 38 years/male<BR>employed by the organisation since: 1989<BR>A 320 qualification in accordance with JAR 145 Authorisations and LBA approved internal QM<BR>guidelines – Signing for Work Performance / FZE / B1 Airbus /A 320 / all ATA electronical, avionics,<BR>Certification of Aircraft and Aircraft Components – Issue of CRS / FZE / B1 / Airbus A 320<BR>Aircraft electronic technician 38 years/male<BR>employed by the organisation since: 1991<BR>A 320 qualification in accordance with JAR 145 Authorisations and LBA approved internal QM<BR>guidelines – Signing for Work Performance / FZE / B2 Airbus /A 320 / all ATA electronical, avionics,<BR>Certification of Aircraft and Aircraft Components – Issue of CRS / FZE / B2 / Airbus / A 320.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 9<BR>Aircraft electronic technician / aircraft mechanic 26 years/male<BR>employed by the organisation since: 1992<BR>A 320 qualification in accordance with JAR 145 Authorisations and LBA approved internal QM<BR>guidelines – Signing for Work Performance / FZE / B1 Airbus /A 320 / all ATA electronical, avionics,<BR>Certification of Aircraft and Aircraft Components – Issue of CRS / FZE / B1 / Airbus / A 320.<BR>Aircraft electronic technician 31 years/male<BR>employed by the organisation since: 1989<BR>A 320 qualification in accordance with JAR 145 Authorisations and LBA approved internal QM<BR>guidelines – Signing for Work Performance / FZE / B2 Airbus /A 320 / all ATA electronical, avionics,<BR>Certification of Aircraft and Aircraft Components – Issue of CRS / FZE / B2 / Airbus / A 320<BR>Aircraft electronic technician 32 years/male<BR>employed by the organisation since: 1984<BR>A 320 qualification in accordance with JAR 145 Authorisations and LBA approved internal QM<BR>guidelines – Signing for Work Performance / FZE / B1 Airbus /A 320 / all ATA electronical, avionics,<BR>Certification of Aircraft and Aircraft Components – Issue of CRS / FZE / B1 / Airbus / A 320.<BR>1.6 Aircraft information<BR>The aeroplane concerned is an Airbus A 320-200, manufactured in 1990.<BR>The aeroplane is equipped with a fly-by-wire system, i.e. all control surfaces (elevator, stabilizer,<BR>ailerons and spoilers) except for the rudder are controlled electrically by means of an hydraulic actuator.<BR>The hydraulic actuators for the rudder are controlled mechanically. In addition there is a mechanical<BR>back-up system for the rudder and the stabilizer. 7 computers are provided for the primary<BR>control of the aeroplane:<BR>• 2 elevator aileron computers (ELAC) for the elevator and aileron control as well as the control of<BR>the SECs to control the spoilers (global roll computation)<BR>• 3 spoiler elevator computers (SEC) to control the spoilers and as standby system for the elevator<BR>and stabilizer control<BR>• 2 flight augmentation computers (FAC) to stabilize the aeroplane flight attitude, e.g. damping of<BR>the Dutch Roll effect in flight, support of the roll control by turn coordination, rudder trim coordination<BR>in case of engine failure and adoption of rudder travel function depending on speed<BR>Two side sticks in the cockpit, which are not mechanically linked with each other allow manual control<BR>inputs by the crew. The movements of the sidesticks are transformed into electrical signals and are<BR>transmitted to the corresponding computers. Generally the sidestick being moved out of its neutral<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 10<BR>position has priority. If both sidesticks are moved simultaneously, the signals of both sidesticks are<BR>added up with the resulting signal being limited by the maximum travel of one individual sidestick.<BR>If one pilot wishes to take over control he will have to press the "TAKE OVER PUSH BUTTON" on his<BR>sidestick. If he releases the button within 30 seconds, both sidesticks are equal in priority again and<BR>the control signals of both sidesticks will be added up again. If he holds the push button pressed for<BR>more than 30 seconds, his sidestick gets priority and at the same time a green light will light up on the<BR>instrument panel in front of him whereas on the other side a red light will light up. This priority can be<BR>neutralized only by pressing the "TAKE OVER PUSH BUTTON" on the other side.<BR>1.6.1 Case History<BR>Already on 17 March 2001 in Hamburg, ELAC no. 2 failed and was then replaced by a new one. All<BR>tests conducted afterwards showed a proper function.<BR>A second error message of the ELAC no. 2 appeared on 18 March 2001 at Frankfurt during taxiing. By<BR>briefly pulling the circuit breakers of the ELAC no. 2 the crew made a “RESET“ after which no further<BR>error message appeared.<BR>A further error message of ELAC no. 2 appeared in the evening of 18 March 2001 at Moscow Airport,<BR>when the powerplants were started. The aeroplane was parked again and engine shut down. As a<BR>corrective action ELAC no. 1 and ELAC no. 2 were interchanged. The defect, however, persisted on<BR>position 2. Therefore the corresponding circuit breakers were pulled pursuant to the "OPERATIONAL<BR>MAINTENANCE PROCEDURE" (OMP) and in accordance with the "MINIMUM EQUIPMENT LIST"<BR>(MEL) so that the defect was now on position 1. The return flight was conducted in accordance with<BR>the MEL with a functioning ELAC no. 2.<BR>The complaint was entered by the crew into the "TECHNICAL LOGBOOK". At the same day, on<BR>18.03.2001, the aeroplane was delivered to the maintenance organisation in Frankfurt.<BR>1.6.2 Repair<BR>When the aeroplane was taken over from flight operations, the complaint “failure of the ELAC no. 2“,<BR>which the crew had entered into the aeroplane’s Technical Logbook, was erroneously transferred by a<BR>maintenance staff member under an incorrect number into the "GROUND LOGBOOK"(GLB).<BR>During the error search, which was accomplished during the night shift from 18th to 19th March 2001 a<BR>defect in the X-TALK-BUS between ELAC no. 1 and ELAC no. 2 could be localized. It was caused by<BR>a bent connection pin (Pin 6K) in the plug segment AE of the socket for the ELAC no. 1.<BR>The attempt to replace the connection pin without replacing the whole plug segment was not successful.<BR>A safety spring of the connector pin had come out and could not be inserted again. Therefore it<BR>was decided to replace the plug segment AE, but there was a problem, it was no suitable spare plug<BR>segment for this series of airplane on stock. Consequently it was decided to replace all four plug<BR>segments AA, AB, AD and AE. This meant that in a most confined space approx. 420 assigned<BR>connector pins had to be reconnected. As this repair work would take a longer period of time, the<BR>aeroplane was taken out of flight operations.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 11<BR>The work started without having a Maintenance Job Order which would have been required according<BR>to respective procedural regulations.<BR>Location of the ELAC no. 1 in the Avionic Bay<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 12<BR>Rear of the plug with its four segments<BR>It was decided to apply the “ONE TO ONE“ method, i.e. the wires were disconnected one after the<BR>other from the old plug and immediately connected to the new one. The work started on<BR>19.03.2001 in the morning shift with the replacement of the plug segments AA, AD und AE. The<BR>fourth plug segment AB was replaced in the subsequent late shift. The work was accomplished by<BR>adequately qualified aircraft electronic technicians with company internal ratings, so-called B1 and<BR>B2 qualifications.<BR>The designation of the positions of the individual pins on the plug segments was defined by an alphanumerical<BR>coordinate system. The working basis was the "AIRCRAFT WIRING LIST" (AWL)<BR>91-20-33 and the "AIRCRAFT WIRING MANUAL" (AWM) 27-92-19.<BR>The staff members were not sure which page of the AIRCRAFT WIRING MANUAL was the effective<BR>one, as there were two pages which could be applicable for the aeroplane concerned and<BR>which could only be assigned on the basis of the accomplished SERVICE BULLETINS (SB).<BR>In addition to the serial numbers the aeroplanes are distinguished by the status of their equipment<BR>with the validity of the documents for the individual aeroplanes being shown by a consecutive numbering<BR>in conjunction with the term "EFFECTIVITY".<BR>Page 2 of the AWM 27-92-19, Feb. 01/91 shows an effectivity range of 013 up to 018 (bottom left).<BR>The designation POST SB001012 below the effectivity range 013018 on the bottom left means that<BR>this WD applies only to aeroplanes whose effectivity is within the range of 001 to 012, if the SB27-<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 13<BR>1030 has been accomplished; the accomplishment being indicated on the bottom right. The aeroplane<BR>concerned had the effectivity 017 and the SB 27-1030 had not been accomplished, therefore<BR>page 2 was applicable.<BR>This page is applicable to all aeroplanes with an effectivity range of 013 to 018 and 001 to 012,<BR>provided on the latter the SB27-1030 has been accomplished.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 14<BR>This page is applicable among other things to aeroplanes within an effectivity range POST SB<BR>from 001 to 034, provided the SBs listed on the right-hand side have been accomplished.<BR>Page 4 shows the effectivity range from 001 to 034 following the desgination POST SB, this means<BR>that this range applies only to aeroplanes on which the SBs indicated on this page on the bottom<BR>right have been accomplished. Although the aeroplane concerned was within this range, only the<BR>SB27-1084 had been accomplished, but not the SB27-1030, thus the page was not applcable to<BR>this aeroplane. Erroneously the mechanics thought page 4 to be applicable as the SB 27-1084 had<BR>been accomplished on this aeroplane.<BR>On this aeroplane there was a further particuliarity concerning the wiring between the sidestick plug<BR>and the ELAC. All pairs of wires consist of a red and a blue wire which are twisted round each<BR>other. As can be seen from the AWL the twisted pairs are always assigned in an alphanumerical<BR>sequence of the plug segment coordinates in the order red / blue, except for the twisted pairs 0603<BR>and 0597 which were - opposite to the normal arrangement - assigned to the pins 3C/3D and<BR>15J/15K in the sequence blue / red.<BR>According to an information given by the manufacturer in response to an inquiry, Airbus Industry<BR>intend to achieve a uniform wiring for all “fly by wire“ aeroplanes. From a certain type series,on the<BR>wiring of the A 320 series was planned to be identical with the wiring of the A 330 and A 340 aeroplanes,<BR>an interchange of colours was accepted for a certain transition period. The aeroplane concerned<BR>belonged to the transition series as could be seen from the Aircraft Wiring List.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 15<BR>This AWL shows the standard assignment of the pins 3C/3D on the plug segment AA in the area with<BR>the dark background. This assignment is applicable to most aeroplanes of the fleet except for the<BR>aeroplanes with an effectivity range from 001 to 018, which would have applied also to the aeroplane<BR>concerned. For this aeroplane the assignment of the pairs of wires 0603 and 0597 with an interchange<BR>of colours blue/red instead of red/blue shown on a white background is effective.<BR>After completion of the reconnection work during the night shift from 19 to 20.03.2001 a functional check<BR>was carried out. During this check an error message on the ELAC no. 1 appeared. With the error search<BR>a faulty connection of the bridge on the plug segment AA was found and corrected. The mentioned error<BR>message, however, did not relate to the original complaint. Afterwards a functional and control system<BR>check was conducted simultaneously by an aeroplane electronic technician with a B2 qualification and<BR>an aeroplane electronic technician with a B1 qualification.<BR>The functional check was conducted on the right hand sidestick only, although the wiring on the left side<BR>was affected as well. The check was carried out using the “AIRCRAFT MAINTENANCE MANUAL“<BR>(AMM). The following instruction had to be adhered to: “Push the FLT CTL ELAC 1 (2) pushputton<BR>switch. – Move the side-stick around in its two axis from stop to stop”. Following the functional<BR>check, an ELAC system test, a LAND test as well as an EFCS 182 GROUNDSCANNING with hydraulic<BR>pressure were done and afterwards the aeroplane was cleared for operation with a “Release to<BR>Service“.<BR>All the accomplished work was documented in the copied “Actions“ column of the work done by the<BR>previous morning shift.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 16<BR>The action was entered into the „RELIABILITY DATA ON DEMAND“ (ROD), which serves the purpose<BR>of recording and evaluating technical processes in the aeroplane, also under the reference<BR>number which had been copied incorrectly from the TLB into the GLB, and consequently this complaint<BR>and the work accomplished on the aeroplane could later not be found under the actual reference<BR>number.<BR>1.7 Meteorological information<BR>The weather information (ATIS) effective for the runway 18 during the period of the serious incident<BR>was as follows:<BR>Wind: 070°/ 4 kt<BR>visibility: more than 10 km<BR>clouds: FEW 032; BKN 250<BR>temperature/dew point: 04 °C / -04 °C<BR>QNH: 1017; NOSIG<BR>1.8 Aids to navigation<BR>not applicable<BR>1.9 Communications<BR>not applicable<BR>1.10 Aerodrome information<BR>The take-off was conducted from runway “West“ at Frankfurt/Main. The concrete runway is used<BR>only for take-offs into the direction 180°. The runway is 4000 m long with a width of 45 m.<BR>1.11 Flight recorder<BR>The flight data recorder concerned is a solid state flight data recorder (SSFDR) made by Loral-<BR>Aviation-Recorders in Sarasota/Florida. Approx. 470 parameters had been recorded. The flight<BR>data recordings were stored on a CD and sent to Braunschweig to the BFU for the purpose of<BR>evaluation.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 17<BR>The evaluation of the cockpit voice recorder (CVR) was waived as due to the recording duration of<BR>30 minutes, the cockpit voice recordings of the period of the occurrence had already been overwritten.<BR>1.12 Wreckage and impact information<BR>not applicable<BR>1.13 Medical and pathological information<BR>not applicable<BR>1.14 Fire<BR>not applicable<BR>1.15 Survival aspects<BR>not applicable<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 18<BR>1.16 Tests and research<BR>not applicable<BR>1.17 Organizational and management information<BR>1.17.1 Operator<BR>On 31.08.1999, the operator was granted an Air Operator’s Certificate (AOC) by the Luftfahrt-<BR>Bundesamt (LBA) in accordance with JAR-OPS 1.175. One of the conditions to be met for the issuance<BR>of the AOC was the establishment of a quality management system (QM) in accordance<BR>with JAR-OPS 1.035. “An operator shall establish one Quality System and designate one Quality<BR>Manager to monitor compliance with, and the adequacy of, procedures required to ensure safe operational<BR>practices and airworthy aeroplanes.“<BR>The operator has no maintenance organisation of its own, scheduled and unscheduled work is carried<BR>out by an external maintenance organisation on basis of a maintenance contract.<BR>The operator put the maintenance organisation in charge of the conduct of the repair work on this<BR>aircraft.<BR>Pursuant to JAR-OPS 1.900, the Quality System of the operator must comprise, among other<BR>things, the monitoring of the proper accomplishment of all conventionary maintenance actions. This<BR>includes also the compliance with the approved procedures.<BR>The Luftfahrt-Bundesamt had on several occasions, last in the scope of the AOC extension, complained<BR>that the operator lacked sufficient personnel for the required audits. In view of this fact the<BR>maintenance system was approved only subject to conditions.<BR>1.17.2 Maintenance Organisation<BR>The maintenance organisation was granted the JAR -145 approval by the LBA on 23 October<BR>1992. Under the JAR-145 approval the maintenance organisation is obliged to comply with the<BR>regulations of JAR-145 and to accomplish the procedures in accordance with the JAR-145 maintenance<BR>organisation's exposition approved by the LBA (QM manual parts 1 and 2), the first issue of<BR>which was approved by the LBA on 28.10.1992.<BR>Part of this QM manual were, among other things, provisions concerning quality requirements and<BR>ratings of the technical personnel in charge of the accomplishment of maintenance tasks and of the<BR>staff in charge of the release of aircraft and aircraft component maintenance.<BR>As at that time the JAR-66 had not been completed yet, the Joint Aviation Authorities (JAA) and the<BR>Federal Ministry of Transport (BMV) had determined that until the coming in force of JAR-66 the<BR>existing national rules should continue to be applied.<BR>At that time the maintenance organisation modified the qualification structure for aircraft mechanics<BR>from a three level system (aircraft mechanic I to III) into a two level system with the designation B1<BR>and B2. In cooperation with the LBA additional qualifications were defined to allow a group of persons,<BR>which in the beginning was limited in number (approx. 25), to carry out special - highly critical<BR>– double inspection (formerly inspection tasks), e.g. following work on the control system. Those<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 19<BR>staff members have to undergo special further training and must have gained practical experience.<BR>The LBA required the passing of an examination before the examination board for inspectors of<BR>aeronautical products.<BR>The designation of the check rating B1 and B2 is a merely internal designation and does not correspond<BR>to the designations of Certifying Staff under JAR-66.<BR>According to information obtained from the LBA, the number of the staff members holding a double<BR>inspection rating (B2) had increased during the years to 140 staff members at the time of the incident.<BR>1.17.3 Supervision of the maintenance organisation by the Luftfahrt-Bundesamt<BR>The maintenance organisation is subject to approval and supervision by the LBA. The responsibility<BR>for the supervision of all four facilities of the organisation and approx. 92 stations lies with one<BR>technical inspector of the LBA, who has to supervise besides the company concerned also two<BR>other German and three foreign organisations.<BR>The Division U3 of the LBA, Maintenance, has got 12 technical inspectors for the approval and the<BR>supervision of 145 aircraft operators, 29 maintenance organisations (9 of which are abroad) and<BR>65 flight training organisations.<BR>Generally one annual audit of 2 to 3 days per facility is scheduled. Supervision in the strict sense of<BR>the word takes place only on the level of the regulations and rules as described in the quality management<BR>manual.<BR>The quality management manual part 1 and part 2 is a part of the LBA approved quality system of<BR>the maintenance organisation concerned. Part 1 mainly defines the administrative items whereas<BR>part 2 describes the rules of quality management. The procedural instructions, which are based<BR>mainly on the quality management handbook part 2, are subject to checks on a random basis only.<BR>Out of the total of approx. 360 effective procedural instructions in the organisation 254 apply to<BR>aeroplane maintenance, of which 173 apply to the area concerned in this case.<BR>1.18 Additional information<BR>1.18.1Documentation<BR>In the following the documents which were available to eliminate the complaint are indicated.<BR>The “AIRCRAFT MAINTENANCE MANUAL“ (AMM) issued by the manufacturer Airbus Industrie as<BR>well as the Electronic Standard Practices Manual (ESPM) served as a working basis for the repair<BR>of the aeroplane according to the ATA (AIR TRANSPORT ASSOCIATION) Specification no. 100,<BR>29th revision.<BR>In addition the following internal documentation was applied.<BR> The Standard Practices Manual of the maintenance organisation (SPM) contains the procedures<BR>for the maintenance of the aircraft of particular customers. Some of the procedures<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 20<BR>contained in the SPM are supplements to the existing manuals of the aircraft manufacturers and<BR>the maintenance organisation. Others are aircraft manufacturers’ procedures modified by the<BR>engineering departments of the maintenance organisation.<BR> Quality Management Handbook for “qualification requirements and ratings of personnel<BR>assuming production tasks“. This handbook describes the system and the responsibilities for<BR>the qualification, ratings and the granting of ratings for personnel charged with production tasks<BR>in the maintenance of aircraft and aircraft components and in the manufacturing of aircraft components.<BR>The responsible accomplishment, inspection and certification of maintenance work on<BR>aircraft or aircraft components, of manufacturing of aircraft components as well as their release<BR>to service may be effected only by production personnel trained and qualified in accordance<BR>with the qualification system described in the QM handbook.<BR> Quality management handbook - system and responsibilities for double inspections. This<BR>QM guideline describes the system and the responsibilities for the provision of double inspection<BR>in the scope of quality inspections in the maintenance of aircraft, aircraft components and in<BR>the manufacturing of aircraft components. Generally it will be sufficient if the staff member who<BR>has carried out the work conducts a self-check of his work for compliance with the requirements<BR>in the scope of his responsibility. For special tasks an additional double inspection is necessary,<BR>which is to be accomplished by a second staff member holding at least the same qualification.<BR>In the corresponding internal procedure are the requirements for double inspection to be described<BR>as easy to handle instruction for the transformation into work paper.<BR> The associated procedural instruction dated 01.04.2000 refers to the a.m. QM manual and<BR>describes the system and responsibilities for work on the aircraft control system. Prior to any<BR>work on the control system it is to be verified by an aircraft mechanic B2/mechanic III whether<BR>the work to be carried out is complex or simple. For complex work the principle of first-check<BR>and double inspection is to be applied. The double inspection is to be accomplished by adequately<BR>qualified personnel and to be certified in the Technical Log Book (TLB), the Ground Log<BR>Book (GLB) and in the list of complaints.<BR> The procedural instruction “Confirmation of Work“ contains instructions for the certification<BR>of work accomplished. It comprises the certification of maintenance work carried out, the airworthiness<BR>release of maintained aircraft and aircraft components relating to the maintenance accomplished<BR>as well as the certification of the manufacture of aircraft components in the scope of<BR>maintenance or the release under the approval as a production organisation.<BR> The procedural instruction “Double Inspection in Aircraft Maintenance“ describes the system<BR>and responsibilities for the accomplishment of double inspection in aircraft maintenance<BR>and for this refers to the corresponding QM guideline. For work on aircraft and aircraft components<BR>quality inspections for the purpose of product quality assurance are to be conducted. For<BR>certain actions this requires besides the first-check also a double inspection.<BR>For the certification of this check it is a general rule that the double inspection is to be conducted<BR>by a staff member holding at least the same rating as the staff member who has carried<BR>out the first-check.<BR> The procedural instruction “Handling of the Technical Log Book“ contains a description of<BR>the system and the responsibilities concerning the TLB. According to JAR-OPS 1.915, the opBFU<BR>German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 21<BR>erator is obliged to keep a TLB as a part of the aircraft log book system. Among other things the<BR>TLB has the following functions:<BR>- recording of maintenance actions accomplished<BR>- confirmation of operator’s receipt of the aircraft from the maintenance organisation<BR>- recording of complaints in flight and on the ground as well as recording of the subsequent<BR>actions, their certification and release to service<BR>- etc.<BR>For all complaints entered into the TLB the corrective actions must be described and certified in<BR>the TLB also. Entries in the TLB must not be changed retroactively.<BR> The instruction for the handling of the “Ground Log Book and the list of complaints” describes<BR>the layout and the system for the handling and filling in of the list of complaints and the<BR>GLB. In the framework of aircraft maintenance, these sets of forms are provided to record and to<BR>deal with complaints. The correct application allows the systematic recording of complaints and of<BR>corrective actions as needed for reliability investigations and error search.<BR>In addition these forms contain blocks for the certification of the corrective actions accomplished,<BR>may serve as a basis for the subsequent entering of the data into a digital system for the administration<BR>of complaints and meet the requirement for the production of evidence pursuant to the provisions<BR>for JAR-145 maintenance organisations.<BR>1.19 Useful or effective investigation techniques<BR>Special investigation techniques have not been applied.<BR>2. Analysis<BR>2.1 Operator<BR>JAR-OPS 1.890 specifies operators’ responsibility for maintenance. In accordance with JAR-OPS<BR>1.900, Subpart M, operators are obliged to monitor that maintenance contracts are complied with.<BR>For this purpose an audit plan, which has to be approved, must be submitted to the LBA once a<BR>year. According to the investigations of the BFU, the operator had not audited the maintenance<BR>organisation and thus the quality system of the operator was not in a position to recognize systematic<BR>faults with the procedural organisation in time. The quality system of the operator is obliged to<BR>monitor the maintenance organisation, to supervise, assess and, if necessary, to demand the quality<BR>of the work performed.<BR>The fact that the malfunction had not been recognized during the flight control check by the crew is<BR>due to the fact that the ailerons had only been checked for full deflection, as described in the check<BR>list, but not for the correct direction of deflection. The BFU have issued a corresponding safety recommendation<BR>to the operator concerned and to the LBA for operators of fly by wire aeroplanes to<BR>amend their check lists accordingly; such an amendment is also in compliance with the recommendations<BR>given by the manufacturer.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 22<BR>On the basis of the investigation the BFU assume that the immediate and prudent action of both<BR>flight crew members at the time of the incident had prevented an accident. The philosophy of a flat<BR>cockpit hierarchy between both pilots which is taught and practised in the operator’s fleets may<BR>have decisively contributed towards the prevention of an accident.<BR>On the part of the manufacturer there was an attempt to explain the fact that during the flight control<BR>check following the delivery of the aeroplane to the maintenance organisation the ailerons<BR>moved correctly for a short time before they deflected in the opposite direction. The conditions on<BR>which this explanation was based, however, existed neither on the ground nor in the air.<BR>2.2 Maintenance Organisation<BR>After the conversion to JAR-145 the maintenance organisation had successively transferred the<BR>inspection tasks. These had previously been reserved to the inspection organisation, into the production<BR>sections in the scope of a transition programme continuously communicated to the LBA.<BR>JAR-145 does not define precise criteria for the qualification of maintenance personnel, but requires<BR>only a qualification system to be specified in the maintenance organisation's exposition.<BR>For personnel in charge of the release of aircraft and/or the maintenance of components, JAR-145<BR>required at that time the application of national regulations until the coming into force of JAR-66. In<BR>the Federal Republic of Germany have never been national requirements for certifying staff. Articles<BR>104 through 111 of the Personnel Licencing Order, which was effective at the time of the incident,<BR>only describe the qualification requirements for inspectors of aeronautical products, whose<BR>tasks pursuant to the Approval of Aeronautical Products Order only consisted in technical inspections,<BR>i.e. a sub-quantity of maintenance tasks. According to national aviation regulations the release<BR>certification of maintenance work was at that time reserved to persons "authorized to sign"<BR>who were not necessarily also inspectors of aeronautical products as for that has never been a legal<BR>basis either.<BR>When the first JAR-145 approvals were issued to JAR-145 organisations it would have been necessary<BR>to amend the Approval of Aeronautical Products Order, in order to preclude problems of<BR>interpretation. This synchronous amendment of the Approval of Aeronautical Products Order was<BR>omitted at that time, meanwhile the Approval of Aeronautical Products Order is no longer effective.<BR>There were several shortcomings concerning the organisation and the accomplishment of work as<BR>well as the quality assurance of the responsible maintenance organisation.<BR>The elimination of this technical complaint was a complex action on the control system, as defined<BR>in the relevant procedural instruction. Prior to starting repair work on 19 March 2001 a maintenance<BR>job order would have had to be established which describes the work, the checks and the documentation<BR>have to be made. This maintenance job order was established on 20.03.2001, after the<BR>had already started, indicating a certain carelessness in the realization of the prescribed working<BR>procedures.<BR>In the morning shift on 19 March 2001 an aircraft electronic technician holding a B2 qualification<BR>was to replace the plug segment AE according to the “ONE by ONE” method with the assistance of<BR>an aircraft electronic technician B1. During this action it was determined that the new segment (AE)<BR>was incompatible with the three remaining segments of the plug. The possibility to find a fitting plug<BR>segment within an adequate period of time would generally have been an alternative, but for internal<BR>reasons another decision was made. If only the segment AE would have had to be replaced<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 23<BR>only the pair of wires 0603 of the monitor channel could have been interchanged on this segment,<BR>the pair of wires 0597 of the Command Channel on the segment AA would have remained untouched<BR>and with a high probabiltiy an error message would have appeared on the display of the<BR>electronic centralized aircraft monitoring system (ECAM).<BR>The reconnection of more than 420 pins of the whole plug was connected to a high risk of errors.<BR>Thus it would have been necessary to measure each individual wire (continuity check) as required<BR>by the manufacturer’s instruction AMM 20-52-10 for major actions on the control system. In reply to<BR>the enquiry of the mechanics to staff members of the Maintenance Support Department, whether<BR>each individual wire should be measured, this action was orally cancelled with reference to the<BR>SPM of the organisation. The reason stated for this decision was the technical experience from<BR>practice that the functional test to be performed after completion of the work would reveal wiring<BR>errors. Erroneously the SPM of the organisation left this decision to the discretion of the staff<BR>members of the Maintenance Support. Following the occurrence this condition was immediately<BR>corrected.<BR>In the Standard Practices Manual the procedure which would have had to be applied in this case is<BR>unambiguously established. This provision could have been cancelled only in writing in the form of<BR>an engineering order. In the opinion of the BFU the omission of the continuity check was not allowable<BR>with regard to the severity of the actions on the control system.<BR>It was also inadmissible to perform the functional check and the control system check simultaneously,<BR>they would have had to be carried out independently of each other. The person who had<BR>conducted the double inspection and thus was the last to have the chance to find the interchanged<BR>connection had not been informed sufficiently about the previous work flow. Presumably it was not<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 24<BR>known to him that the staff members of the late shift had by direction of the Maintenance Support<BR>not measured the reconnected wires, as actually required.<BR>As a further omission, the control system test and the functional test were made only from the righthand<BR>sidestick and not from both sidesticks and a comparing visual check of the control surfaces of<BR>the aeroplane was waived completely.<BR>The fact that the manufacturer's instruction in the AMM 27-93-00-710-050 (-Push the FLT CTL<BR>ELAC 1 (2) push button switch - Move the side-stick around in its two axis from stop to<BR>stop.) was not unambiguous, was the reason why the test was conducted only from the right-hand<BR>sidestick. The a.m. instruction of the manufacturer had meanwhile been changed at the suggestion<BR>of the maintenance organisation and now requires mandatory tests from both sidesticks.<BR>The question of the BFU staff members why the tests had been conducted from the right-hand<BR>sidestick which was not concerned was answered with the statement that it did not matter which<BR>sidestick was used. As both ELACs were connected to each other possible faults of the one or the<BR>other ELAC would surely be indicated. This statement indicates lacking system knowledge of the<BR>mechanics.<BR>Severe errors in the conduct of the first check and cross-checks arose. Presumably the aircraft<BR>mechanics involved who carried out the checks underestimated the significance of the previous<BR>action. There is no other explanation for the fact that the cross checking staff member had conducted<BR>the required cross-check using the working documents which where aboard the aircraft and<BR>had already been used by the staff member having conducted the first check, although according<BR>to the regulations he would have had to use his own impartial documents. Obviously the imporBFU<BR>German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 25<BR>tance of the cross-check to this repair had not been realized. In this case not the workflow but the<BR>independence of the cross check was the crucial factor.<BR>The repair organisation quality system required pursuant to JAR-145 had proved to be insufficient<BR>in this case. In addition it has become obvious that in this case there are deficits in the accomplishment<BR>of prescribed procedures and in the necessary system knowledge of the staff members.<BR>2.3 Documentation<BR>Since the reference number was mixed up when the complaint was copied from the TLB into the<BR>GLB, the previous maintenance action could not be found initially in the “RELIABILITY DATA ON<BR>DEMAND“ immediately following the occurrence. Even though this error is not directly related to<BR>the cause of the confusion of the pairs of wires it indicates that the quality system did not work optimally.<BR>A complicated and complex documentation system which thus is difficult to handle increases the<BR>risk of mistakes. The 173 procedural instructions valid for the area concerned contain many cross<BR>references making handling considerably more difficult. It was very time-consuming to find out<BR>which procedural instructions were relevant to the tasks to be performed.<BR>In the past, the maintenance organisation made great efforts to establish an internal documentation,<BR>which exists parallel to the manufacturer’s documents and like them has always to be kept up<BR>to date. Diversions from the manufacturer’s documents have in this case resulted in actual mistakes.<BR>The aeroplane manufacturer classified the occurrence as a maintenance error, which will not lead<BR>to changes in aeroplane design. The ambiguous instruction in the AMM was amended on the insistence<BR>of the maintenance organisation immediately following the occurrence.<BR>Towards the BFU the manufacturer justified the problem of the colour interchange red/blue -<BR>blue/red between the side stick connector and the ELAC plug with the objective of obtaining a uniform<BR>wiring of all fly by wire aeroplanes A 320, A 330 and A 340 which previously had differences.<BR>This applies to a certain A 320 transition series, which includes the aeroplane concerned. This particularity<BR>involves an increased risk of errors. In the opinion of the BFU, the manufacturer should<BR>have more plainly and more emphatically pointed out this particularity.<BR>2.4 Supervision by the LBA<BR>The depth of supervision as could be achieved by the technical inspectors of the LBA led to a condition<BR>in which deficiencies in the organisation and accomplishment of work and in the quality assurance<BR>with the operator as well as with the maintenance organisation had not been recognized. It<BR>does not seem to make sense that such a large organisation as in this case falls within the purview<BR>of only one technical inspector of the LBA who is also responsible for several other organisations.<BR>For reasons of capacity, the technical inspectors are not in a position to check the organisations<BR>more thoroughly. Especially in the organisation concerned plenty of internal provisions had been<BR>compiled in the course of the years, the contents of which were not sufficiently known to the technical<BR>inspectors. Up to February 2001 only one technical inspector of the LBA was responsible for<BR>the operator as well as the maintenance organisation, now this task is shared by two LBA staff<BR>members, which, however, still seems to be insufficient.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 26<BR>2.5 Illustration of the causal chain<BR>The investigation has revealed that numerous factors have contributed to this occurrence. The<BR>causal chain was never interrupted. In order to illustrate this the Swiss Cheese Model according to<BR>Reason was modified in to a chronological sequence.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 27<BR>3. Conclusions<BR>3.1 Findings<BR>• The maintenance organisation is certified by the LBA and has been working under JAR-<BR>145 since 1993.<BR>• The entering of the incident into the Ground Log Book and into the "Reliability-Data on<BR>Demand" (ROD) under an incorrect reference number shows a lack of care.<BR>• The complicated design of the damaged pin (6K) on the plug segment AE of the ELAC # 1<BR>did not allow a repair in confined space.<BR>• The decision to replace the whole plug was a consequence of the fact that a suitable spare<BR>part was not on stock.<BR>• The decision to reconnect the wires of the whole plug involved a high risk of errors.<BR>• The decision which pages of the Aircraft Wiring Manual were applicable was very difficult<BR>to make on the basis of the accomplishment or non-accomplishment of SBs on this aeroplane.<BR>• The prescribed interchange of colours within the pairs of wires 0603 and 0597 between the<BR>sidestick and the ELAC plug was not realized by the mechanics probably because of the<BR>complicated documentation.<BR>• The work of the late shift on the plug segment AB was inadmissibly entered into the same<BR>field of the GLB in which already the work of the morning shift on the plug segments AA,<BR>AD and AE had been copied, instead of being entered into a separate column.<BR>• The malfunction “PITCH TRIM FAULT“ which had occurred during ground scanning after<BR>completion of the work was not related to the confused wires.<BR>• The technical personnel was adequately licensed to accomplish the work.<BR>• The qualification of the B2 or the mechanic III personnel having attended a one day additional<BR>training course to obtain the cross-check rating cannot be equated with the qualification<BR>of an inspector of aeronautical products or of certifying staff under JAR-66.<BR>• The cross checking staff member did not carry out an independent cross-check as he had<BR>incorrectly used the documents of his colleague who had done the previous work.<BR>• The measuring of the individual wires was considered unnecessary by Maintenance Support<BR>and therefore omitted.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 28<BR>• The duplicate inspections, i.e. functional check pursuant to the AMM and control system<BR>check pursuant to the Job Order was conducted incorrectly due to the fact that the provisions<BR>were not unambiguous.<BR>• Contrary to the instructions not all of the inspection modes available were used for the<BR>checks.<BR>• Due to deficiencies in the quality system of the maintenance organisation, errors in the organisation<BR>and the accomplishment of work remained undetected.<BR>• The operator had not performed the audits in the maintenance organisation required by<BR>JAR-OPS thus the deficiencies in the maintenance organisation could not be realized.<BR>• The LBA had not recognized deficiencies in the quality system of the operator and the<BR>maintenance organisation.<BR>• The flight crew of the A 320 was adequately licensed to conduct the flight.<BR>• After start-up of the powerplants, the lateral control of the aeroplane was checked in accordance<BR>with the “AFTER START CHECKLIST“ only for full deflection but not for the correct<BR>direction of deflection.<BR>• During lift-off the aeroplane assumed a slight bank angle to the left. The attempt to counteract<BR>this tendency was not successful due to the left sidestick being incorrectly connected.<BR>The bank angle even increased to approx. 22°.<BR>• The First Officer took over the control of the aeroplane and immediately restored the normal<BR>flight attitude.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 29<BR>3.2 Causes<BR>The BFU has come to the conclusion that the serious incident is due to the fact that:<BR>• during repair work on the plug of the Elevator Aileron Computer (ELAC) no. 1 two pairs of<BR>wires had been connected inverted<BR>• the error remained undetected<BR>• the error was not recognized by the flight crew during the “FLIGHT CONTROL CHECK“.<BR>Contributing factors were:<BR>• an unclear and difficult to handle documentation so that a wrong wiring diagram was<BR>used<BR>• diversion from the manufacturer’s data by the Maintenance Support<BR>• manufacturer’s instructions which are not formulated unambiguously<BR>• functional check by the cross checking staff member was carried out incorrectly<BR>• iinsufficient functioning of the quality assurance<BR>• the lack of supervision of the maintenance organisation by the operator<BR>• a quantitatively and qualitatively insufficient supervision of the maintenance organisation<BR>and the operator by the supervising authority.<BR>• deficiencies in the “AFTER START CHECKLIST“ for the conduct of the “FLIGHT<BR>CONTROL CHECK“.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 30<BR>4. Safety Recommendations<BR>4.1 Immediate Actions<BR>As an immediate action the BFU issued the following safety recommendation to the LBA and to the<BR>aircraft operator concerned:<BR>Recommendation no. 09/2001<BR>The procedures and checklists for all fly by wire aeroplanes should be amended in such a way that<BR>during the flight control check attention is paid to the correct direction of movement of the ailerons<BR>and roll spoilers as recommended also by the manufacturer.<BR>4.2 Actions during the investigation<BR>4.2.1 Internal actions by the maintenance organisation<BR>Due to the serious incident a series of internal immediate actions were initiated in order to preclude<BR>as far as possible that such an occurrence will happen again. A large number of medium and longterm<BR>actions have mostly been realized already in the course of investigation. They shall contribute<BR>to the creation of new working conditions and human relations as well as to the bulding up of a<BR>more distinct sense of responsibility.<BR>• As an immediate action an instruction has been issued that the functional and control system<BR>checks on fly by wire aeroplanes must always be performed from both sidesticks. The<BR>Standard Practices Manual (SPM) as well as the Job Cards have been amended accordingly.<BR>Airbus Industrie have been requested to correspondingly amend unclear wordings in<BR>the “AIRCRAFT MAINTENANCE MANUAL“. The staff members involved in this process<BR>have received instruction.<BR>• Within the scope of the short-term actions mainly internal processes, quality assurance<BR>procedures and the rules for the documentation of maintenance actions have been<BR>checked and modified. The continuation training of the staff members has been intensified.<BR>• Within the scope of medium term actions an improved familiarization of newly employed<BR>personnel with all necessary operational procedures has been achieved and accordingly<BR>documented. The exchange of information should be improved. An anonymous reporting<BR>system similar to that in flight operations has been installed, in order to allow staff members<BR>to complain about inacceptable requirements or technical and other conditions without<BR>taking a risk of personal disadvantages.<BR>• The long term objective is a positive change in the attitude to work and working ethics intended<BR>to lead to an improved working culture.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 31<BR>4.2.2 Actions of the Luftfhart-Bundesamt (Federal Office of Civil Aeronautics)<BR>To improve the situation of the supervision of the operators’ maintenance systems the LBA in<BR>agreement with the BMVBW has shifted the emphasis of work to the supervision of the approved<BR>maintenance systems. This action which is at the cost of other tasks is for the present limited until<BR>mid 2003.<BR>At the same time additional funds for personnel have been requested and promised for the budgetary<BR>year of 2003.<BR>4.3 Safety recommendations following the completion of the investigation<BR>Recommendation no. 05/2003<BR>The actions initiated by the Luftfahrt-Bundesamt should be continued for an unlimited period beyond<BR>the year 2003 in order to achieve a permanent qualitative and quantitative improvement of the<BR>audits to be performed with the aircraft operators and the maintenance organisations.<BR>Recommendation no. 06/2003<BR>The aircraft operator should provide the organisational and personnel conditions in order to ensure<BR>compliance with the quality requirements for the maintenance of aircraft in the maintenance organisation<BR>in accordance with the requirements of JAR-OPS 1.035 (Subpart B) in conjunction with JAROPS<BR>1.890, 1.895, 1.900, 1.905 (Subpart M).<BR>Recommendation no. 07/2003<BR>The systerm of the procedural instructions in the maintenance organisation should be amended<BR>and re-arranged so that procedural instructions are clear, unambiguous and readily findable for all<BR>users.<BR>5. Enclosures:<BR>The enclosures have been included in the text.<BR>BFU German Federal Bureau of Aircraft Accidents Investigation<BR>5X004-0/01 32<BR>Braunschweig, 19.05.2003<BR>Bundesstelle für Flugunfalluntersuchung (Federal Bureau of Aircraft Accidents Investigation)<BR>by order<BR>Müller<BR>Investigator-in-charge<BR>The following BFU staff members have contributed to the investigation:<BR>J. Reu&szlig;<BR>A. Thiel

涟漪雨 发表于 2010-11-11 09:58:24

Thanks a lot!
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