Introducing Crow Instability and Wake Turbulence Augmentation
 

Flight 587 Crash Case Covers Wide Range of Key Safety Issues

The investigation into the fatal crash of an American Airlines [AMR] twinjet may illustrate that the vaunted ethic of industry partnership on safety issues can be severely eroded, shifting from comity to confrontation, when the liability monster raises its head.

Beyond the smoke and thunder of controversy lies a potential solution for immediate mitigation: modified departure procedures based on wind profiler data to avoid encounters with wake vortices. Such an encounter was the triggering event in the Flight 587 crash.

 The controversy over cause is amply illustrated by the ongoing investigation into the fatal Nov. 12, 2001, crash of American Flight 587, which involved an Airbus A300- 600 twinjet. The composite tailfin separated from the Airbus jet, causing it to plunge into the Belle Harbor residential area in New York City, killing all 260 aboard and five persons on the ground.

The accident marked the second time in recent years where structural failure was involved in loss of control. On Jan. 31, 2000, an Alaska Airlines [ALK] MD-83 twinjet was lost with all 88 souls on board off the coast of Los Angeles, Calif., when the horizontal stabilizer separated from the aircraft.

National Transportation Safety Board (NTSB) investigations into both crashes are proceeding. Of the two, the Alaska crash may be simpler, as the remedy to the failed jackscrew that caused the stabilizer to break off the airplane's T-tail is at hand in terms of a failsafe design developed by engineers at the Kennedy Space Center (see ASW, Nov. 18).

The A300 crash is considerably more complex, involving issues of pilot-machine interaction, wake turbulence, rudder system and composite structure design and certification, and possibly even modified air traffic control procedures. The range of issues and their significance could have a profound impact.

The two cases do have one aspect in common: in both cases, immediate actions were taken in response to malfunctioning flight control systems. On the Alaska jet, the pilots reset the circuit breakers controlling the jackscrew motors moving the horizontal stabilizer perhaps as many as eight or nine times, according to documents released as part of the investigation. Each time the breakers were reset, the re-energized motors stripped more thread off the acme nut connecting the stabilizer to the tailfin. On the American jet, a malfunctioning yaw damper was reset before takeoff. Some sources believe both cases may reveal symptoms of system failures which, particularly in the latter case, may not yet be fully appreciated.

During the NTSB's recent hearings into the A300 crash, Airbus officials denigrated American's upset recovery training program for the emphasis it placed on rudder use (which American representatives vigorously denied was misplaced). For their part, American officials countered that the airplane and its A310 cousin had a history of inadvertent high tail loadings, and that Airbus had not advised of any restrictions on rudder use below maneuvering speed - at least not until months after the accident.

The four days of hearings evidenced more of the high drama of a courtroom proceeding than a dry, dispassionate discussion of technical issues (see ASW, Nov. 4, & Nov. 11).

To summarize:

  • It was not proven that the pilots, and First Officer Sten Molin, the pilot flying, moved their rudder pedals. Despite circumstantial evidence pointing in this direction, the DFDR sampling rate and necessary interpolation would seem to make any such finding inconclusive.
  • On the other hand, it has been demonstrated that the rudder load limiter did not restrict the rudder to limit load or below ultimate load (fail-country, as it were). Furthermore, it has been demonstrated that two other incidents have occurred where the autopilot did not declutch from the rudder channel and design loading was exceeded on the tail. In both of those cases, the rudder pedals moved on their own for the duration of the event, sources say.
  • From what has been gathered thus far, the regulated design standards affecting all manufacturers may not provide sufficient margins for what is believed by some were the actions of the accident crew. It is now deemed unsafe to apply the rudder first one way and then the other, because the first application yaws the plane such that aerodynamic forces on the fin and rudder will be that much higher when the rudder is reversed.
  • Other incidents that may bear on the Flight 587 case are yet to be addressed, such as the Nov. 25, 2001, airspeed fluctuations on a

     Singapore Airlines A340 during uncommanded yawing (i.e., overspeed warnings and large rudder movements without pilot input, according to initial reports).

  • The Airbus checklist for dealing with an unlocked landing gear, since changed, called for alternating rudder inputs to induce back-and-forth sideslips to lock the gear in place. Some sources assert that this procedure involved doublets (full opposite deflection of rudder without stopping at the neutral position). Use of opposite rudder is now restricted to engine-out and crosswind landing scenarios.
  • Following a 1997 incident in which ultimate load was exceeded on the tailfin of another American A300, the airline and manufacturer Airbus were at odds with each other over the sharing of digital flight data recorder (DFDR) information, which the manufacturer deemed vital to understanding the event and which the airline apprehended could be used as grist in legal proceedings against it. The notion of partnership in problem solving and of "data-driven" safety was significantly challenged.
  • With the Flight 587 crash, and all the uncertainty and controversy surrounding it, the case has never been stronger for more capable DFDRs, quick access recorders (QARs), cockpit voice recorders (CVRs) and for closed circuit television cameras (CCTV). One might argue that over the life of any airplane, the ability to accurately dissect accident outcomes should be as important as certifying its airworthiness. One of the great limitations in the Flight 587 case is the absence of data on forces applied to the sensitive rudder pedals. Movement was recorded, not force. The pilots unions have an incentive to get on the bandwagon for improved recorders, as they can see now that one of their number, unfortunate to qualify as an accident pilot, is being subjected to postmortem allegations of incompetent malfeasance.

It may be useful to probe deeper into various aspects of the case.

Pilot actions and the reconstruction video

The video produced by the NTSB shows pictures of the plane and the attitude indicator, along with graphic displays of the positions of the rudder pedals and the rudder. The re- creation was all derived from filtered DFDR data and the CVR.

As the plane taxis, one can see the yaw damper/auto-coordination system functioning. As the aircraft exits the taxiway and turns onto the runway, the rudder deflects left without the rudder pedal moving, i.e., the "system" thinks the aircraft is yawing nose right and makes corrective action. When the aircraft stops on the runway, the rudder deflects right, which then slowly decays to zero (centered), again without the rudder pedals moving.

These indicators suggest that the rudder control system was functioning properly.

During the first wake encounter with the Japan Air Lines (JAL) B747-400 that preceded Flight 587, the rudder moves slightly on the DFDR tracings, but the rudder pedals hardly move - suggesting that feet were on the pedals but they were used with great restraint.

The second wake encounter is extremely short - about 10 seconds from start to tailfin separation - and extreme coordinated yoke and rudder pedal movements are shown almost from the start. In a freeze-frame of the second wake vortex encounter, the pedal limiter was overpowered but the rudder limiter was not. Throughout the final fatal sequence the rudder does not move outside of its system limit of 10º deflection (at that speed, 250 knots) left or right. A cautionary note: the DFDR is not capturing virtual reality - it was sampling rudder movement at a rate of twice per second. Given the rudder's ability to move at 39º per second, it could move left or right nearly to its full limit and back to the centered position within the sampling interval.

The rudder pedal positions were being sampled at twice per second, also. Some pilots who originally thought it was impossible to impart four rudder reversals inside seven seconds now concede that they had no idea that pedal movement of just 1.3 inches would command a full 10º deflection. They now say that just pressing with toes conceivably could move the pedals that rapidly.

Airbus officials testified during the hearings that if the pilot applies 130-140 pounds of pressure on the pedals, the variable rudder stop could be stalled, and the mechanical "elasticity" of the rudder control system might actually result in the rudder moving beyond its programmed limit. However, in the event of such a limiter stall, a warning chime will sound in the cockpit. No such warning was captured on the CVR. So, apparently, the pilots did not stall the variable stop. Additionally, there is no valid (i.e., unfiltered) evidence that the rudder panel moved outside limits. The evidence in this regard may be a point of even greater concern, because it suggests that a failure may be caused below maneuvering speed by a to-and-fro cycling of the rudder panel without it going out of limits.

In any event, the DFDR readout shows four full opposite yaw damper oscillations and five full-travel opposing pedal movements in the last seven seconds that the tail was attached. The yaw damper shows a classic sine wave with a lengthening period over the seven-second interval, while the pedal movement shows greater excursions both in and out of phase with the yaw damper. During one two-second period the rudder pedal was in the full right position. The scenario that comes to mind might be described as a "man in the loop system induced oscillation" (SIO).

Rudder control system design

Given the minimal movement needed on the pedals, if Capt. Ed States was resting his feet on the pedals, he may have had no cause for alarm, not realizing that each perceived slight movement of the pedal, unlike the four inches of available pedal movement on the ground, was fully deflecting the rudder. He voiced no concern on the CVR about Molin's control inputs. States may have been anticipating emerging momentarily from the turbulence and saw no reason for undue concern or correction. After all, wake turbulence encounters are not rare.

Indeed, by unconscious comparison with the four inches of pedal movement felt during the rudder performance check conducted just before takeoff, the pedal movements during the second vortex encounter might have impressed States as being rather restrained.

Airbus officials believe the light forces on the pedal enable pilots to more accurately control the airplane. Some pilots agree.

Others assert that the forces, 22 pounds to overcome friction plus another 10 pounds to move the pedals, are so light that it could be difficult to modulate control of the rudder. This school of thought holds that the pilot may well lose any feel for the center position fairly quickly, and that going from full left to full right is easier in feel than going from neutral.

One pilot suggested an automobile analogy, in which the brakes become more sensitive with an increase in speed: "Picture a car going 80 miles per hour and the only thing that will happen if you touch the brakes is that the wheels lock."

This comparison may not be entirely apt. On the A300, with an increase in speed both the allowable pedal input and rudder output are increasingly restricted.

Rudder system certification standards

As a consequence of the Flight 587 accident, certification standards are under scrutiny. The regulations as published by the Federal Aviation Administration (FAA) outline only a maximum rudder pedal force of 150 pounds, but no minimum. Also, there is no standard ratio of breakout force to the force required to achieve maximum displacement of the rudder pedals. Is 10 lbs. from a 22-lb. breakout to a 32-lb. maximum at 250 knots appropriate? What about the relatively small distances the pedals move at higher speeds? On some other aircraft, the pedal movement at 250 knots is even less than that for the A300.

Nor do the regulations address the structural strength needed for rapid back-and-forth deflection of the rudder. Erhard Winkler, an Airbus senior composites engineer, said at the outset of his prepared presentation to the NTSB, "The most important thing for an aircraft structure is that it should be strong enough to resist all load conditions as required by FAR 25 [Federal Aviation Regulations, Part 25, which applies to airliners]." Winkler did not say "strong enough to withstand all possible loads." Yet there are seven cases where limit loads were exceeded on the A300 and its A310 cousin. In five of those cases rudder doublets were involved. Three of those events (including Flight 587) went beyond ultimate load, and doublets were recorded in each of those events.

In six of the seven cases where limit load was exceeded, rudder pedal movement was recorded, and doublets were recorded in five of those six cases. This itemization presented by Airbus during the hearings suggests that pilots are making inappropriate use of the rudder. Capt. Bob Tamburini, an A300-600 pilot, sharply disputes any such intimation. "Why are there so many A310/A300-600 aircraft that have experienced incidents of significant loading?" he asked in a recent communication to this publication. "Do pilots, once they qualify in these aircraft, immediately take stupid pills?"

More broadly, the absence of any consideration in the regulations for rudder doublets is striking in light of what has been known and for how long. Consider the conclusion from this 1946 National Advisory Committee for Aeronautics report of dynamic loads on the vertical tail:

"An oscillating rudder deflection of small amplitude causes large loads that are reached in a short time. The rudder motion necessary to maximize the load is very moderate because of the low natural frequency of the airplane. One cycle executed in 8 seconds is sufficient to raise the load on the vertical tail surfaces to 2400 pounds per degree. An amplitude of only about 9º would therefore be necessary to cause failure of the tail with this type of deflection. The initial cycle of a fishtail maneuver may be considered as a rudder reversal and its critical nature is shown by the fact that 86 percent of the load corresponding to final resonance is attained with only 1 cycle of rudder motion.

"The importance of this type of control-surface deflection is recognized for the horizontal-tail load, and present requirements specify a standard elevator deflection ... for computing critical loads. A need is seen ... for the vertical tail ... of what is required ... in regard to yawing maneuverability."

One question posed at the hearing but not directed to any particular individual was "How can we continue to certify an aircraft that can be broken by use of its certified flight controls?" The answer given was along the lines that it has always been the case that aircraft can be broken by the use of pitch controls, and pilots have been expected to stay within the pitch envelope. So, too, are pilots now advised to stay within the yaw envelope.

Cases of High Loading on the Tailfin
Date
Aircraft
Rudder Pedal Movement
Rudder Doublet
Tailfin Load
Nov. 2001 A300-600 (Flt. 587) Yes Yes 1.96 LL (limit load)
May 1997 A300-600 (Flt. 903) Yes Yes 1.53 LL
May 1989 A300-600 Yes Yes 1.11 LL
March 1999 A300-600 No No 1.16 LL
Feb. 1991 A310 (Interflug) Yes Yes 1.55 LL
Sept. 1994 A310 Yes No 1.12 LL
Nov. 1999 A310 Yes Yes 1.06 LL
Source: NTSB, Docket SA-522, Exh. 7-Q

Maneuvering speed limits

Critics charge that the word has been slow in coming out on a subject of such fundamental importance as the maneuvering envelope of the airplane. It has been traditionally understood that full use of the flight controls can be made within that envelope. Indeed, the accident aircraft was within the bounds of the maneuvering envelope when the numerous roll and yaw movements were recorded. Interviewed after the accident by the NTSB, Capt. Paul Railsback, American's managing director of flight operations, was specifically asked about his understanding of maneuvering speed and if it provided protection against sequential and opposite deflections of the rudder. "I would expect it to," he replied (see ASW, Nov. 11).

A recently retired B777 captain from another airline demurred, saying, "I've never thought the definition of maneuver speed was meant to include rapid inputs including rapid reversals."

"It's true that if you lose the right engine at V1 (say, 145 knots) you will not hurt the airplane if you whap the rudder full left to maintain directional control. But it is not true if VA is 270 knots that you can whap the rudder full left, full right, full left, etc., without causing something to break. That was never the intended definition of VA," he argued.

Indeed, in a March 2002 flight crew operating manual (FCOM) bulletin to A300/A310 operators, Airbus cautioned against the notion of unrestricted use of flight controls at speeds within the VA envelope:

"Sudden commanded full, or nearly full, opposite rudder movement against a sideslip can ... result in structural failure. This is true even at speeds below the maximum design maneuvering speed, VA."

If this interpretation is now the received wisdom in the industry, it represents more than a technical clarification and affects operating procedures. Consider the 270-knot speed mentioned by the pilot above. That is coincidentally the maximum speed at which the landing gear can be extended on the A300-600. If the crew receives a warning chime that the gear is lot down and locked, note the difference in FCOM procedures before and after the Flight 587 accident:

Before: "If one gear remains unlocked, accelerate to Vmax ... and perform alternating side slips in an attempt to lock the gear." (FCOM, Rev. 25)

After: "Sideslip should be initiated using the rudder on the same side of the aircraft as the unsafe gear indication, i.e., if the right main landing gear is unlocked, slowly apply right rudder up to full deflection if necessary while maintaining wings level to generate sideslip. If the gear still fails to lock, then slowly return the rudder to neutral ... and then slowly apply opposite rudder. If necessary, repeat this cycle in an attempt to lock the gear." (FCOM, Rev. 26)

It should be noted that American eschewed this procedure, enjoining its pilots to bank the aircraft to one side then the other in an attempt to lock the gear. The carrier that has been charged with advocating excessive rudder use in upset recovery did not advocate rudder use as an expedient action drill to resolve an unlocked landing gear warning.

In any event, the whole issue of VA may trace back to that 1946 NACA paper, and its concern about how easy rudder reversals can induce ultimate load and its urging that strength requirements for the tailfin need to be more clearly specified. During the course of the NTSB hearings, reference was made to a "Russian-type" maneuver. Apparently, the Russians require sufficient strength to withstand a rudder doublet as part of their certification standards. The NACA paper brought up this critical point some 56 years ago.

Data sharing

In an industry where the sharing of data is seen as key to advancing safety, documents released as part of the Flight 587 crash reveal the opposite. American officials groused that the manufacturer had not apprised them of previous incidents where the A300/A310 experienced extreme loadings. Among them, the successive stalls of an Interflug A310 in February 1991 in which the tailfin experienced 1.55 limit load. Nor, said American officials, had they been advised of the 1.53 limit load experienced by their Flight 903 during a May 12, 1997, stall event involving an A300.

Dispute Over Data

 

May 20, 1997, e-mail from American Airlines Tulsa maintenance base, to Airbus (extracts):

"I urgently need your thoughts ... if the [Flight 903] aircraft did stall, I need an explanation why there was no stick shaker.

"Did someone from Airbus tell the NTSB that the aircraft should have stalled? If this is true, how could they possibly make this statement without seeing the DFDR?

"Gentlemen, between the legal department using the DFDR and this last (reported) statement from Airbus, I'm now in an extremely sensitive situation and our credibility is going down the toilet fast."

(ASW note: by design the stick shaker warns of the approach to stall. If the stall is encountered dynamically, as in the case of Flight 903, stick shaker action may be quite brief, and lost or not noticed in the ensuing activity. If the stick shaker was to operate continually by design, i.e., once stalled, its action might serve to confuse and complicate recovery.)

June 20, 1997, internal Airbus e-mail (extracts):

"AAL initially reluctant to release the DFDR as well as any inspection results did so recently.

"AAL were informed about our serious concern ... and that we refrained from putting the aircraft on the ground only because of the inspection results received from them today.

"Another concern I would like to raise is that ... we should retain carefully the evidence to claim compensation if this aircraft will show damage which was not discovered now and inform AAL accordingly." Source: NTSB, Docket No. SA-522, Exhibit 7-LL  

"This information was never handed to the NTSB or to the parties [to the investigation]," groused Tim Ahern, American's vice president of safety, during the hearings.

Airbus' John Lauber countered that American was advised by e-mail at 6:13 p.m. on June 19, 1997, that the Flight 903 airplane had likely experienced ultimate load and needed to be inspected "as early as possible." A follow-up e-mail was sent just two hours later, "We kindly ask you to send to Airbus Industrie urgently the details of the inspections ... top priority should be given on the rear part of the aircraft."

"The event was 12 May, why the delay?" Lauber asked Michel Curbillon, the Airbus witness at this point in the hearings.

"We needed more DFDR information," Curbillon replied.

Lauber then charged that three days after the May 12 upset the carrier had refused to release the requested DFDR information. The exchange of messages over release of the DFDR data reflect a high degree of frustration between the two parties.

NTSB member George Black said unhappily, "I am concerned about the flow of information in the [Flight] 903 case."

The tailfin, having passed two visual inspections in 1997, was deemed airworthy and remained in service on the incident aircraft for five years, until it was removed after the Flight 587 crash for non-destructive examination (NDE). Additional calculations further confirmed that the fin had experienced more than ultimate load in the 1997 event and it was not returned to service.

Composite materials

The Airbus philosophy with respect to composite materials received a big boost from an independent expert during the hearings. Airbus engineers have argued, in the face of considerable criticism, that damage to composite materials not detected visually is not sufficient to compromise structural strength, and that even hidden damage below established thresholds will not grow or worsen in service (see ASW, July 29). Dr. Jim Starnes, a senior composites expert at the National Aeronautics and Space Administration (NASA) testified that after his detailed examination of the engineering data, he agrees with the "no growth approach for flaws below a critical size."

"At this point, I don't think we have a materials degradation issue over time," he said.

Starnes' statements are not likely to end the controversy. On March 22, the FAA issued AD 2002-06-09 mandating inspections of the tailfins of any A310/1300-600 aircraft that encounter lateral loads of 0.3G or more. Tamburini and other A300-600 pilots who have banded together to voice their concerns to the FAA believe this AD points to potentially unresolved aspects of composite durability under high loading. These pilots point to other ADs affecting other aircraft with composite structure that raise concerns with respect to delamination, cross-ply cracking, and moisture/freeze damage.

For example, AD 2001-09-03 calls for ultrasonic inspection for possible disbonds between the skin and substructure (spars, ribs and stringers) of the A330 composite vertical fin. AD 2002-03-11 essentially calls for the same thing on the A319/320/321 series. Potential disbonding is significant since it could, as the AD states, "lead to reduction in the structural integrity of the spar box." In other words, such disbonds could lead to catastrophic failure.

Wake vortex encounters

Flight 587 was in a climbing turn at the time of the accident, and it encountered the second wake vortex from the preceding JAL jet at a more acute angle than its passage through the first. As a consequence, the airplane was travelling right amidst the wake vortex turbulence for a significantly longer time. NASA meteorologist Fred Proctor described wake vortices in general as "mini weak tornadoes."

Strongest when they spill off the wingtips, the vortices were about 60-80 percent of their original energy when Flight 587 encountered them. The different computer models used to estimate them explain the variance, Proctor explained. Also, by then, the vortex energy was oriented differently in relation to the flight path of the following airplane.

A unique combination of circumstances may have played out its deadly implications in the Flight 587 accident, according to an August 2002 engineering study. Anthony Brown, an engineer-pilot at the Flight Research Laboratory of the Institute of Aerospace Research, an arm of the National Research Council (NRC) of Canada, evaluated the potential for adverse airplane-pilot coupling along a flight path through a series of vertical-axis vortices. His scenario could have implications for wake vortex encounters because situations exist where the pair of trailing vortices mutually attract each other. Brown explained that as they move together, each vortex induces the other downward. Eventually, the pair link together to become a series of "arched over" individual vortex rings, which then break down (the image of smoke rings comes to mind). Known as "Crow instability" (named after its discoverer), the process can last from 30 seconds to a minute.

A following airplane flying through rather than across these rings could experience a series of sharply defined directional load pulses. If each pulse meant a yaw axis swerve, the sensation might have stimulated Molin into trying to correct with rudder pedals. Brown estimated in his paper that flying through a series of vertical vortex elements would produce sideslip angles of up to 10º along with "extremely dynamic reversals"(the analogy of hammer blows comes to mind).

The pilot's immediate corrective responses could be exactly out-of-phase, leading to forces on the tailfin of 1.3 to 1.6 of limit load. Using a simplified reactive pilot model to study the potential interaction, Brown wrote, "There is observed to be significant coupling between pilot-actuated rudder deflections and induced sideslip ... upon approaching and penetrating each vortex core." In fact, he went on to say, twice limit load could be reached in short order with this "rudder/vortex" coupling effect - very close to the 1.96 limit load at which the tail broke off Flight 587.

Brown referred to the Flight 587 accident scenario in his study. The accident airplane experienced lateral forces of 0.3G, about which Brown wrote: "Noting that resting frictional force is generally about 0.3G, any lateral acceleration or acceleration reversal above this value would ... accelerate any and all objects. Suddenly seeing and/or hearing any object move sideways across the cockpit with an instant flurry would likely be the 'GO' trigger to commence reactive control inputs, a commencement which would be unlikely to involve conscious decision-making. Indicators of a lack of conscious decision-making would be the control input rates and a lack of any remark from the pilot regarding intended actions."

This is precisely what the DFDR and CVR data show in the Flight 587 case - rapid rudder pedal movement and nothing more remarkable in the way of verbal utterances than Capt. States' query, "You all right?" followed by, "Hang onto it" about two seconds before the tailfin broke away.

Again, recall that early NACA paper - 86 percent of limit load in one rudder reversal - and it may all come together:

Crow instability + transiting along the wake + a powerful rudder system + a light touch on the rudder pedals + the pilot's reactive control inputs = structural failure

In a telephone interview, Brown said, "We need more flight measurement data to see if the scenario I realized can be seen in practice."

"The critical point for this directional-stimulation scenario is at the edge of the vortex core" where it is oriented vertically, he said. Separation standards, he went on to explain, are based on wake pairs, which generally result in rolling encounters. "Pilots are not trained to respond to these rare [vertical] encounters," Brown added.

He pointed out that, according to Exhibit 14-B in the investigation docket, when an attempt was made to replicate the Flight 587 turbulence encounters in NASA's vertical motion simulator, test subjects reported that it did not evidence much lateral acceleration in the cockpit of the A300-600 flying through turbulence. That missing side-sway is associated with the vibrating mode of fuselage flexure, Brown explained. It would be an important element in the pilot's "seat of the pants" feel during a wake encounter. The absence of this important element probably stems from the fact that the DFDR did not appear to record linear accelerations in the flight station, Brown explained. "Yet the pilot response will be determined by how disconcerting the encounter feels," he added.

Brown said the kind of vortex instability he's talking about occupies only "a small period of space and time for the trailing aircraft." Nonetheless, he went on to say, jetliners must be built to cope with even rare encounters. For design and certification purposes, he said, the probability must be considered as 1.0. "It's a question of what airplanes may encounter, however infrequently," he said. In the absence of more data, he said, that frequency might be seen "in the odd accident along the way, each of which is an accident too many."

In the meantime, even if the chance of such a combination of factors occurring again is remote, what is to be done to avoid a repeat? Capt. Paul Miller of

 the Independent Pilots Association has an idea. He believes that radar-based wind profiler technology could be employed to fill a current void in weather reports.

The wind profiler Doppler radar system measures horizontal and vertical winds, from low altitude to high, and produces picture-type profiles of the winds aloft. Not unlike balloon soundings, the profiler shows just a "slice" of the atmosphere above it, not two miles or 20 miles away. In other words, every eddy that forms won't be detected unless it occurs over the wind profiler. On the other hand, the profiler gives a constant sampling, a big advantage over balloons, which provide a sampling only once every six or 12 hours when they are sent aloft.

Air traffic controllers could use the wind profiler data to keep subsequent departures "upwind" of preceding traffic, especially when wake vortex avoidance is desirable. This kind of adjustment to current practice would not be nearly as draconian as an increase in separation standards. Miller envisions other potential applications:

  • Flightcrews could be provided more accurate wind field data to conduct precision approaches during instrument and night conditions.
  • With more accurate wind data at lower levels, ATC could adjust vectored flight patterns and reduce track deviations caused by high winds at low altitudes. Winter winds of more than 50 knots can often occur at altitudes as low as 3,000 feet, Miller noted, which can wreak havoc on ILS (instrument landing system) downwind and crosswind patterns.

Miller said the wind profiler technology, currently used to support space launch operations and atmospheric research programs, has yet to be exploited for commercial airline operations. "Here is an example of what can be done quickly and effectively to improve safety," Miller asserted. "If pilots can be held accountable for knowing how to operate in the windfield, then FAA ATC and weather services should be tasked with providing more wind field information."

And should the Crow instability phenomenon turn out to be more common than thought, the wind profiler reports could be exploited by ATC to avoid a repeat of the Flight 587 tragedy.

>> The NACA report may be viewed at http://naca.larc.nasa.gov/reports/1946/naca-report-838/naca-report-838.pdf. Brown, e-mail anthony.brown@nrc.ca; more on wind profiler may be viewed at http://www.ofcm.gov/r14/front.htm; miller, e-mail PaulLMiller44@cs.com; Tamburini, e-mail Tambo700@aol.com <<

 
 

Safety Board Calls for Design Changes to Airbus Rudder System

"The sensitivity of the system is critical and needs to be addressed."

 Safety Board Member Debbie Hersman

Modifications are needed to nearly 500 Airbus A300-600 and A310 aircraft in order to provide pilots with greater protection from hazardous rudder pedal inputs at high airspeeds that can lead to aircraft pilot coupling (APC), the National Transportation Safety Board (NTSB) decreed Oct. 26.

These aircraft share the same rudder control system. Capping a three-year $3.7 million investigation into the Nov. 12, 2001, crash of American Airlines Flight 587, an A300-600, the safety board held the design partly responsible for the crash, which killed all 260 aboard and five persons on the ground at the Belle Harbor, N.Y., impact site.

At the end of the daylong hearing, NTSB Vice Chairman Mark Rosenker said, "We've seen today a tragic coupling of the pilot and aircraft that brought down Flight 587."

Pending system modifications, the board said that pilots need to be advised in no uncertain terms that back-and-forth pedal inputs to the rudder, or rudder reversals - even within the certified "maneuvering speed" (VA) - pose the risk of imparting aerodynamic loads high enough to break the fin, as was the case in the Flight 587 crash.

While the board's exhaustive inquiry exonerated the composite materials used in the A300-600 rudder and tailfin, and ruled out terrorism (no evidence of a bomb explosion), investigators criticized American's upset recovery training program, decried the apparent withholding of safety-critical information in an earlier incident, and blasted the continued use of "filtered" flight data recorder (FDR) information.

Above all, the NTSB homed in on the rudder control system. "It is an inherently unfriendly design," said the NTSB's Malcolm Brenner.

In the statement of probable cause, the board cited First Officer Sten Molin's "unnecessary and excessive rudder pedal inputs."

This ultimate judgment, that the pilot flying caused the crash, was expected. An animation of the control wheel and pedal inputs show a series of dynamic control inputs well beyond any modest adjustments needed to fly the airplane through the wake turbulence it encountered from a Japan Air Lines B747 that had taken off from New York's John F. Kennedy International Airport immediately ahead of Flight 587.

However, in its recitation of contributing factors in the crash, the safety board cited rudder pedal inputs that were "characteristic of the A300-600 rudder system design" (i.e., its sensitivity) and, in implied secondary order of importance as a contributing factor, the negative learning inherent in American's advanced aircraft maneuvering program (AAMP). The acronym is a synonym for upset recovery training. As pointed out in this publication, a wake encounter is a transitory atmospheric condition and not an "upset" importing loss of control (see ASW, Oct. 25).

By its action, the safety board has cast a shadow over the rudder system design, which may require the manufacturer to undertake a potentially costly modification and retrofit.

American officials, who apprehended that the rudder system might be exonerated, leaving AAMP as the primary contributing factor, clearly were heartened, if not elated, by the board's action.

"We really agree with the recommendations on the rudder sensitivity issue," declared Bob Reding, senior vice president for technical operations at American Airlines.

Airbus issued a statement immediately following the hearing reflecting the manufacturer's disappointment and surprise at the board's determination. "We do not believe the facts of the investigation point to sensitivity of the rudder as contributing to the accident," Airbus said flatly.

Investigators deemed Molin's control inputs much too aggressive when the airplane encountered the first of two wake vortices (which were slipping off the wingtips of the JAL jet a few miles ahead).

"The bumps from wake turbulence were typical and the effect on the airplane was minor," said the NTSB's John O'Callaghan. Some American officials contend that the forces may have been greater but not captured by the low sampling rate of the flight data recorder (compounded by "filtering" mentioned below). The strength of the wake vortex aside, it is known that Molin made large inputs to the control wheel, shown in an animation as rather like moving the steering wheel of one's automobile in a sudden quarter-turn. When the airplane encountered the second wake vortex, Molin made full left and right control wheel inputs as well as a series of opposing pedal inputs. American officials contend that Molin's initial input with a force of about 30-35 lbs. suggests he did not intend to apply full rudder. However, subsequent rudder inputs were on the order of 140 pounds.

"The airplane was outside of its normal flight regime when the fin separated," O'Callaghan said.

The composite fin broke at nearly twice its limit load. Limit load is defined as the worst case loading expected in normal service. To this value, a 50 percent safety factor is applied called ultimate load (i.e., 1.5 of limit load). The attachment lugs to the fin broke at 1.93 of limit load. Post-accident analysis and testing showed no evidence that the composite layers in the fin had delaminated or degraded in service. Three other attachment lugs were tested after the Flight 587 accident. All three lugs held well above ultimate load before breaking.

The key question is what prompted Molin to alternatively move the rudder pedals like an exercise machine to the point where the structure failed?

NTSB staff member David Ivey said American's AAMP training, which Molin had completed, may well have predisposed him to use rudder. Specifically, Ivey said, during the simulator portion of AAMP training, pilots were presented with an "unrealistic wake turbulence encounter." The airplane was rolled beyond 90º angle of bank and the flight controls were inhibited until the aircraft rolled to that point.

Neither pilots nor AAMP instructors at American knew that the simulator flight controls were inhibited (i.e., washed out) until this point. For an airplane about to roll on its back, rudder would be an appropriate response. Thus, Ivey surmised, the inhibited flight controls may have "conditioned use of the rudder."

Above all, Ivey found that rudder pedal travel and rudder pedal force were thought to be unchanged at higher airspeeds. "AAMP did not fully explain the airplane's response to rudder inputs," Ivey said. In particular, "That rudder pedal movement decreases with an increase in airspeed and increases in sensitivity with an increase in airspeed."

During takeoff, the pedal moves four inches to full deflection and requires a force of 65 pounds to move. At 250 knots airspeed in climb, the point where the accident sequence occurred, the pedal requires only 32 pounds of force (only 10 lbs. above the 22-lb. breakout force) and moves only 1.2 inches to achieve maximum deflection.

Steven Magladry, an NTSB systems engineer, said the rudder system on the A300-600 "has the lightest force and the shortest travel of any other airplane." Moreover, he added, there are no quantitative standards, or measures of sensitivity, for certification. Given the absence of any such measure, the NTSB created its own. It relates G-force felt in the cockpit to every pound of force applied to the rudder pedal. Investigators compared the A300-600 system to that of the A300 B2/B4, the predecessor model from which the A300- 600 was derived. Magladry explained that B2/B4 operators had called for reduced control wheel force, which Airbus engineers sought to honor in the A300-600 design. In order to maintain "harmony" with wheel and rudder pedals, the engineers also reduced the forces required to move the pedals.

The result was an A300-600 design whose sensitivity increases with an increase in airspeed, unlike that of the B2/B4.

"We don't like the change in sensitivity from low speed to high speed," said John Clark, NTSB head of aviation accident investigations. "However, we don't know how far off the 240 knot point you need to be to have a safe system," he said, referring to the 0.02 G force imparted by pedal movement at that speed. "We want to buy more margin," he said, to reduce the potential for aircraft pilot coupling (APC).

APC is a phenomenon in which pilot control inputs can be out of phase with the airplane's reaction, tending to negatively reinforce an increasing deviation from desired to actual aircraft response. In the case of the Flight 587 accident, APC may well have been involved in the rapid series of rudder reversals leading to fin separation. Prior to the Flight 587 accident, few pilots were aware that APC was possible within the rudder circuit (i.e., around the yawing axis). Classic APCs have tended to be in pitch, with a minor number seen as instability around the fore-aft axis and known as roll-coupling. APC involves an involuntary interaction. The nature of the APC beast is that once the process is set in train, it is unlikely that any pilot will suddenly "get off" the controls. Disengagement is not intuitive.

Brenner, an NTSB human performance specialist, said, "APC events always reflect some underlying design characteristic."

"Staff concludes that the A300-600 is susceptible to potentially hazardous coupling at high airspeeds," Brenner said.

Magladry added that the pedal stop "is a moving target" that also depends on the functioning of the yaw damper.

While the board issued recommendations in early 2002 for pilots to be cautioned in training about the dangerous potential for rudder reversals (see ASW, Feb. 18, 2002), Vice Chairman Rosenker said, "At this point, we haven't done much about the rudder - its sensitivity."

Board Member Debbie Hersman said, "The sensitivity is more important than the AAMP program."

"It is important to address both equipment and training, but we must make sure that the equipment and its response to pilot's input does not create an unexpected environment," she added. To support her contention, she noted that:

  • In one of Molin's two previous encounters with wake turbulence, he had not used rudder. On the one previous occasion where he had used the rudder, it was after AAMP ground school but prior to the simulator training. AAMP, therefore, may not have conditioned him to apply rudder. By implication, she was pointing to the potential for APC in the accident sequence. After the first rudder input, Molin was involved in an APC event. Moreover, while rudder should not be needed to maintain control in a wake upset, a special 1995 review of 33 wake encounters logged in the aviation safety reporting system (ASRS) database over a six month period showed that pilots used corrective rudder inputs in 11 such cases. Again, if pilots are going to apply rudder, such application should not precipitate APC-induced reversals.
  • Hersman noted that the A320 rudder system may be similarly sensitive as the A300-600's, and therefore the design issue may extend to other models. Magladry remarked that the A320 "has a short pedal throw and less force at higher speed, but we don't know how the airplane responds at higher speed." He noted that the A320 is a fly-by-wire (FBW) design, where the system automatically will "input aileron to reduce sideslip" and the attendant aerodynamic forces on the tailfin.
  • Hersman pointed out that of seven high loading events, three occurred among A310 operators whose pilots did not go through AAMP training. By implication, AAMP was not a common culprit, pointing again to the rudder system's sensitivity.

By these arguments, the board was moved to recommend design changes to provide increased protection from hazardous rudder pedal inputs at higher speeds for the A300-600 and A310 fleets. If protection against APC is inadequate in the face of rudder inputs at all airspeeds, the aircraft deemed vulnerable should be modified - a recommendation that could extend beyond the A300-600 and A310 fleets.

The Flight 587 accident also led to the headwaters of the great river of certification standards. Member Hersman noted that aircraft designers are required to show that the fin is strong enough to bear the aerodynamic forces associated with full rudder deflection, followed by return to the neutral position. They are not required to demonstrate the forces associated with a reversal - full deflection to one side followed by continuous movement in the opposite direction to full deflection on the opposite side. Hersman's exchange with Ivey, a former airline pilot, shows the arbitrariness of the certification standard for a pilot who unexpectedly gets full rudder from 1.2 inches of pedal travel.

NTSB Chairman Ellen Engleman-Connors said the issue of rudder reversals during certification needs to the examined "as a follow up item" with the view to new airplane designs being able to "handle reversals."

Other issues of import beyond the A300-600 and A310 and the Flight 587 crash were raised that have implications for the industry in general.

For one thing, NTSB officials sharply criticized the use of "filtered" FDR data. Because of filtered recorder data, O'Callaghan said, "We didn't really have a true rudder position. It had to be reconstructed through a tedious process."

As previously indicated in this publication, the controversy over filtered data has come up before and the NTSB had to have been aware of the use of filtered FDR data on some aircraft, having tacitly approved exceptions allowing the use of filtered data on some aircraft models (see ASW, Aug. 5, 2002)

Nonetheless, the board wants raw data recorded, and it wants this capability incorporated within two years. One year has already passed since that recommendation was issued, with no evidence of progress. Accordingly, NTSB board members reclassified the status of their recommendation from "Open - Acceptable Response" to "Open - Unacceptable Response."

Of perhaps greater concern to board members was the perception that Airbus had not shared all it knew about fin loads during the May 1997 stall/upset of Flight 903, another A300-600 (see ASW, Oct. 25). As in the Flight 587 accident, the Flight 903 incident involved rudder reversals, but NTSB officials investigating that event were not made aware of the high loads put on the fin. Sources say as much as 1.9 of load limit may have been achieved, nearly that of the 1.93 of limit load experienced on the Flight 587 accident aircraft.

In the 1997 upset, the rudder deflected some 63 percent beyond the RTL (rudder travel limiter) at 250 knots airspeed (where the Flight 587 accident airplane experienced structural failure of the fin four years later). A June 16, 1997, Airbus internal memorandum expressed considerable concern over the high loads:

"The reason is that the load due to sideslip ... and the load due to rudder deflection will work in the same direction and must be added up. Rudder movement from left limit to right limit will produce loads on [the] fin/rear fuselage above ultimate design load."

"These high amounts and [their] combination are not covered by Loads Design Maneuvers according to JAR/FAR 25 [the European and U.S. certification standards]."

This was one of the memoranda that prompted Airbus to urge American Airlines to inspect the fin and report the findings. However, in its Aug. 12, 1998, submission to the NTSB on the Flight 903 investigation, Airbus did not mention the RTL exceedances or that ultimate load might have been reached on the fin.

Clark said, "We did not know of the specific [loads] calculations and the actions of the RTL, and we're not very pleased with the subsequent revelations."

Engleman-Connors declared, "The moral obligation [to share information] will always be higher than the legal obligation [in] my opinion."

First Officer John David, deputy safety committee chairman of the Allied Pilots Association (APA), the union of American Airlines' pilots, hypothesized that if the full implication of the fin loadings in the Flight 903 incident had been known, the NTSB recommendations to avoid reversals - issued in February 2002 after the Flight 587 crash two months before - might have been issued in 1998 after the Flight 903 upset, possibly averting the Flight 587 disaster.

Yet during the board hearing last week, NTSB officials discounted a relationship between the Flight 903 event and the Flight 587 accident, while at the same time complaining that Airbus had not disclosed all it knew. Clark said the two cases involve different circumstances. "We don't think there's a 'eureka' piece in 903 that would have led us to 587," Clark said. However, the NTSB's listing of similarities and differences in the two cases did not include rudder reversals. Those movements, and the resulting high tailfin loads, add to the similarity in the two cases.

What lies ahead is the manner in which design changes, if any, are introduced to the A300-600 and A310 rudder control systems to reduce sensitivity and their potential for APC. Certification standards, and whether rudder reversals should be a required element, have been deferred as an issue for the moment, but the NTSB has vowed to look closer. The NTSB clearly seeks added protection against APC in those standards.

In the meantime, Reding said American has already implemented recommended changes to AAMP. Flight control effectiveness is no longer suppressed. Rather, the simulator session starts by putting the airplane into a 90º bank and a -35º pitch and freezing it in this position. The orientation is then unfrozen, and the pilot is challenged to recover the airplane to level flight with full control authority.

The Difference Between Certification Standards & The Real World

NTSB Member Debbie Hersman: If you are a line pilot, how likely would it be that you would get the full amount [of rudder]? Or get 1.2 inches of the pedal at 250 [knots airspeed]?

NTSB professional staff member David Ivey: If I were to put in rudder? And knowing what I had found that ... there was a very good chance you could put in full rudder [with 1.2 inches of travel]?

Hersman: And if you put in full rudder to the right, how likely is it that you're going to have to come back with the left rudder?

Ivey: I think I could speak for most pilots that if I had any input that had sent me to the right, for example, I'm not going to do what certification says and put my rudder to neutral. I am going to counter the effects that I have just experienced in my body or what I have seen and I'm going to put in opposite rudder to try to correct the problem ... But to answer your question, if I had a big yaw to the right I would put in left rudder. I certainly wouldn't put it in neutral.

Hersman: And once that happened, is it your belief that this pilot was in an APC?

Ivey: It is my belief. Source: NTSB

Airbus: 'We are surprised'

"While the facts of the investigation show that the first officer inappropriately used rudder - as he believed he had been trained by American Airlines to do - we are surprised by the Board's concern about rudder pedal sensitivity at extremely high speeds in the context of this investigation (as reflected in the probable cause established by a divided 3-2 vote).

"We do not believe the facts of the investigation point to sensitivity of the rudder as contributing to the accident. The first officer applied tremendous pressure on the rudder pedals - about 140 pounds of pressure on several occasions - which would have resulted in full rudder reversals on any commercial aircraft anywhere in the world. Clearly, the pilot was seeking full application of rudder, something he would have achieved regardless of the sensitivity of rudder pedals." Source: Airbus

Rudder Design Data for Selected Airbus and Boeing Models All data at an airspeed of 250 knots
Aircraft Model Pedal Force (lbs) Pedal Travel (in) Rudder Deflection (deg)
Airbus
A300-B2/B4
125
4
9.3
A310
32
1.2
9.3
A300-600
32
1.2
9.3
A320
36
1.2
8.3
A330-300
45
1.24
9.5
A340-300
45
1.24
9.5
Boeing
B767
80
3.6
8.0
B737
50
1.0
4.0
Source: NTSB

Similarities & Differences Factors in the Flight 903 Upset in 1997 Affecting the Flight 587 Accident in 2001
Issue AA 903 AA 587
Pilot training Yes Yes
Stall/loss of control (LOC) Yes No*
Rudder input necessary to recover Yes No
High speed rudder system sensitivity No Yes
Slow moving rudder travel limiter (RTL) Yes No
Issues not mentioned by NTSB in this comparison:
Rudder reversals Yes Yes
Exceed limit load and ultimate load Yes Yes
Filtered flight recorder data Yes Yes
* Assuming aircraft-pilot coupling (APC) does not constitute LOC Source: NTSB, additions by ASW

Aircraft Pilot Coupling Needs to be Avoided During Design

Test techniques have been developed to assess an airplane's susceptibility to aircraft pilot coupling (APC).

The test methods are contained in an advisory circular (AC) published March 31, 1998, by the Federal Aviation Administration (FAA). This document, AC 25-7A, titled "Flight Test Guide for Certification of Transport Category Airplanes," was produced years after the Airbus A300-600 was certified for service in 1988. At the time of its certification, an earlier version of this AC, No. 25-7, was in effect. This earlier document discussed the need to minimize susceptibility to APC and the A300-600 met all certification standards in force at the time.

The 1998 edition of the AC raises the bar for certification purposes by laying out more specific criteria for the evaluation of an airplane design's susceptibility to APC. It features both a numerical rating scale and a characterization ranging from "satisfactory" to "unsatisfactory."

By its nature, APC can be a pilot-entrapment latent flaw, the disclosure or discovery of which is the purpose of flight tests.

The rating scale is to be used by test pilots. To cite from the AC:

  • "Service experience has shown that compliance with only the quantitative, open-loop (pilot-out-of-the-loop) requirements does not guarantee that the required levels of flying qualities are achieved. "
  • "Therefore, in order to ensure that the airplane has achieved the flying qualities required by [Federal Aviation Regulations]

US dollars 25.143(a) and (b), the airplane must be evaluated by test pilots conducting high-gain, closed-loop tasks to determine that the potential of encountering adverse APC tendencies is minimal."

  • "The evaluation of flying qualities discussed herein ... should be accomplished by at least three test pilots."
  • "Only the pilot's rating of the APC characteristics is needed."

Based on the known sequence of events in the 2001 loss of American Airlines Flight 587, the pilot introduced abrupt control maneuvers.

If these movements triggered an APC event, it was necessary for the pilot to release or freeze the flight controls. The four rudder reversals and dynamic, opposing movements on the control wheel, show that he did the opposite - a symptom of a pilot's unfamiliar response to APC (rather than what the Flight 587 accident pilot appears to have thought - that the airplane was encountering an unusually strong wake vortex).

Throughout the Flight 587 investigation, Airbus officials have consistently declared that the accident could have been avoided had the pilot stopped inputting rudder reversals and allowed the airplane to fly through unexceptional wake turbulence.

As Airbus asserted in its submission to the National Transportation Safety Board (NTSB): "The accident would not have happened had the first officer simply taken his feet off the rudder pedals at any time prior to ... structural overload." (See ASW, March 29) Short of releasing or freezing the controls, pilots can endeavor to reduce or escape oscillations by reducing the gain. Regarding the A300-600's sensitive rudder system, modulating - or reducing - the control inputs may be difficult. During last week's final hearing on the Flight 587 accident, the NTSB's Malcolm Brenner said, "The system is so sensitive, it would be difficult for a pilot not to hit the stops."

AIRCRAFT PILOT COUPLING (APC) RATING SCALE
Descriptive Rating Numeric Rating Scale APC Characteristics Description
Satisfactory
1
No tendency for pilot to induce undesirable motion.
2
Undesirable motions (overshoots) tend to occur when pilot initiates abrupt maneuvers or attempts tight control. Those motions can be prevented or eliminated by pilot technique. (No more than minimal pilot compensation required)
Adequate
3
Undesirable motions (unpredictability or over control) easily induced when pilot initiates abrupt maneuvers or attempts tight control. These motions can be prevented or eliminated but only at sacrifice to task performance or through considerable pilot attention and effort. (No more than extensive pilot compensation required)
Controllable
4
Oscillations tend to develop when pilot initiates abrupt maneuvers or attempts tight control. Adequate performance is not attainable and pilot must reduce gain to recover. (Pilot can recover by merely reducing gain)
Unsatisfactory
5
Divergent oscillations tend to develop when pilot initiates abrupt maneuvers or attempts tight control. Pilot must open loop by releasing or freezing the controller.
6
Disturbance or normal pilot control may cause divergent oscillation. Pilot must open control loop by releasing or freezing the controller.
Source: AC 25-7A

Are current wake separation standards adequate?

No, according to a statement issued Oct. 26 by the Allied Pilots Association (APA), the union of American Airlines pilots, following the National Transportation Safety Board's (NTSB) hearing on the Flight 587 crash. Here's what the APA had to say:

"AA587 took off immediately following a Tokyo-bound JAL 747 (which weighed almost 1,000,000 lbs. fully loaded) and began a turn inside the 747's radius of turn. This flight path placed AA587 in a position closer than the takeoff separation and caused the aircraft to encounter a strong wake vortex. The NASA [National Aeronautics & Space Administration] study commissioned by the NTSB rated the vortex at between 63 percent and 80 percent of its original strength. The NASA study also stated that the aircraft encountered sinusoidal oscillations resulting from Crow instability [where the trailing vortices combine, increasing the strength of the wake turbulence], which, unlike a normal turbulence encounter, would lead to a lateral or yawing force being felt in the cockpit.

"Current wake separation standards are inadequate. The 'heavy' class of aircraft now runs from 255,000 lbs. to nearly 1,000,000 lbs. Wake vortex strength is a function of aircraft weight, and with the advent of new, higher gross weight aircraft, ever stronger wake vortices are being produced. It would be much more accurate and prudent to have additional weight categories to define more precisely the wake vortex strength differences between aircraft and further separate the heavier aircraft from the lighter aircraft."