Foreign Object Damage and FOD Prevention

Foreign Object Damage (FOD) can be caused by Foreign Object Debris (called FOD too). FOD can also mean « Foreign Object Detection« . Watch the video, and read its transcript below:

Transcript :

 

Our Air Force has the most technically advanced aircraft in the world – deadly fighters, and bombers, mighty cargo and tanker workhorses, our many helicopters, and a variety of specialty aircraft.

But they can all be easily grounded by FOD.

Foreign objects cause damage to our aircraft in many ways. For example, cut tires, and jammed flight or engine controls. FOD has caused at least six fighter aircraft to crash over the last twelve years! Some of the items that caused these mishaps were:

  • Rags;
  • Safety wire pliers;
  • A piece of aluminum foil;
  • A one-inch piece of safety wire;
  • Even a small washer!

These incidents show that poor housekeeping, and work practices are still the two major contributors to preventable FOD. We can eliminate FOD. To do so, we must make these six commonsense steps, part of our every job, every step, every day.

  1. The first step – be aware that you can make a difference, and that FOD is a constant problem. Every time you sign out a tool box, work a job, or just step out to help someone, keep your eyes open for tools, rocks, and other debris. And when you see something, stop, and pick it up. Occasionally, you may need a sweeper to clean up an area. MAC usually coordinate with base OPS. MAC (Military Airlift Command) usually coordinates this support with base OPS.
  2. The second step – keep your work area clean. Check your shoes for foreign objects, and empty your pockets of keys, change, pencils, and trash. Place these items into a FOD bag before entering the cockpit, intake, other confined areas, or before working on top of the aircraft. Are you covering all of those lines, houses, cannon plugs, and ducts during extended maintenance? The ACES II ejection seat is the most reliable, and safest seat in the world, as long as nothing gets in the way. Somebody did not report losing this pencil tip. It then migrated in flight to the sequence start switch which activates the seat computer as it departs the aircraft. It was discovered during a visual inspection of the seat when it was removed for other maintenance. Because of the protective shield over the switch, and the tight clearance in the cockpit, it normally would never have been found. How do you think the pilots felt when they heard about it? Do you check the area one more time before you leave? It is possible the person before you left something behind.
  3. Step three – we have to keep our vehicles clean. We know foreign objects get around, and many times are, vehicles carry them out to the flight line. Tire checks – are you constantly doing them every time you went to the flight line? How about after you drove out of the taxiway to let the jet pass? How clean is your vehicle? Is there safety wire, trash, or fasteners on the floor? Is the FOD can overflowing before you empty it? If you have a vehicle magnet installed, are you checking it daily?
  4. Step four – Thorough FOD walks. Are you looking, or are you out there just stretching your legs? Pay special attention to the grounding points, and cement grooves, and cracks. These areas are always filling up with trash, rocks, and hardware. A good daily FOD walk helps us keep up with all the debris that still manages to get onto the ramp. A FOD walk should have found this bolt. Instead, it was sucked up, off of the ramp by a B-1. Three first-stage compressor blades, and one inlet guide vane were damaged. It cost us 56 man-hours, and over $ 35,000 to remove and fix this engine.
  5. Step five – good tool and hardware control is a must. Remember the last time you lost a tool, or a nut? How long did you look for it? Did you find it? When was the last tool report started? Remember – tool control starts when you receive a toolbox. Before you sign for it, make sure all missing tools are written up, and check the box for pieces of safety wire, and other trash. Woe, slow down, and look. Is that a tool, or the tool cutout? If you find a tool missing, don’t accept the box, and make sure a last tool report, and investigation is started. Also, never leave tools in hardware in or on the aircraft. Do a good inventory of your toolbox, and TOs* after every job. This alone will narrow the search area, and greatly increase your chances of finding a last tool. Think about it, what would you rather check? One aircraft, or three? When you do find a tool missing, start looking for it immediately. If you can find it after a short search, report it immediately to the expediter, or dock chief, and get some extra help to look for the missing tool or hardware. For tight or inaccessible areas, you can also use a borescope** or X-ray equipment to locate lost items. How would you tell the pilot if the jet has just taxied? What if it is flying? A file about this size was left behind after blending two engine blades on a C-5, possibly fallen behind a nacelle blocker door*** during the job. Four people then signed for the box over the next several days before someone finally noticed, and reported the last tool. The file was not located, and then came loose in flight the next day. This incident caused over 550 men-hours of work, and $ 66,000 in damage to the engine. Hardware control is simply taking only what you need, and counting how many nuts, bolts, or other hardware you take from bench stock. After the job, make sure you account for all the hardware. If you don’t complete the job, annotate the screw bag with the quantity, the type of hardware, and your name. This will help the person who finishes the job track down any missing hardware. Here is what a misplaced ¼ inch nut did to a C-130 engine. Over 30 blades were damaged beyond repair, not counting depot costs – the damages have already taken 64 man-hours, and exceeded $ 38,000 in damages. Sometimes, we accidentally leave items inside the intake danger area, or in the intake before an engine start. These have included VTR tapes, flashlights, cleaning bottles, and aircraft forms. Are you paying attention? Or have you just been lucky?
  6. Step six – follow the T.O.. For tight or inaccessible access areas, you can also use a borescope, or X-ray equipment to locate lost items. How would you tell the pilot if the jet has just taxied? What if it is flying? A file about this size was left behind after blending two engine blades on a C-5, possibly fallen behind a nacelle blocker door*** during the job. Four people then signed for the box over the next several days before someone finally noticed, and reported the last tool. The file was not located, and then came loose in flight the next day. This incident caused over 550 men-hours of work, and $ 66,000 in damage to the engine. Hardware control is simply taking only what you need, and counting how many nuts, bolts, or other hardware you take from bench stock. After the job, make sure you account for all the hardware. If you don’t complete the job, annotate the screw bag with the quantity, the type of hardware, and your name. This will help the person who finishes the job track down any missing hardware. Here is what a misplaced ¼ inch nut did to a C-130 engine. Over 30 blades were damaged beyond repair, not counting depot costs – the damages have already taken 64 man-hours, and exceeded $ 38,000 in damages. Sometimes, we accidentally leave items inside the intake danger area, or in the intake before an engine start. These have included VTR tapes, flashlights, cleaning bottles, and aircraft forms. Are you paying attention? Or have you just been lucky?

6. Step six (again and further) – Follow the T.O.. Several times we have had equipment, and panels come off during an engine run, or in flight, causing serious damage. On the last job before a three-day weekend, an experienced crew chief and his assistant were preparing an F-16 for an engine run. He skipped the warning, and the step to check the run screen safety pin for security. During the engine run, one pin came out, and after whipping around in the intake for a few seconds, the lanyard broke. The pin destroyed over 426 blades. Total cost – $ 69,000 and 366 man-hours. What was the cost of the crew chief? How do you think he felt? Think of what he went through. The de-certification, the investigation, the waiting. Was the two or three seconds saved worth it? Sometimes, confusing or incomplete TOs are part of the problem. Improper installation caused by poor tech aide, and inexperience created a stress crack in the upper anti collision light lens in a KC-10.

* T.O.: Technical Order

** (or boroscope)

*** Thrust reverser (pelle d’inverseur de poussée)

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F-22 Pilots would be Suffering from « Raptor Cough »

F-22 Raptor tight turn
F-22 - © USAF photo Tech Sgt Justin D. Pyle

 

 

 

According to the CBS news video report below, F-22 pilots would have stopped flying 5th-generation F-22 Raptor for they would have reported HH (Health Hazards) incidents onboard the most advanced fighter aircraft in the U.S. Air Force, and the most expensive ever.

 

« The F-22 has been plagued by a mysterious flaw that causes its pilots to become disoriented while at the controls, from a lack of oxygen. »

 

Thanks to this interview, we now know that a pilot would have touched a tree while flying an F-22 as he may have been suffering from hypoxia (oxygen deficiency in body tissue). Some other pilots reported dizziness, vertigo, and coughing spell.

 

« The Air Force launched an investigation that focused on the plane’s On-Board Oxygen Generating System, or OBOGS which takes air from outside the jet, passes through the engine, and through a chemical process to produce a concentrated oxygen that the pilot breathes – Watch the video:

 

 

© USAF photo Tech Sgt Justin D. Pyle, www.af.mil courtesy

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PANIC ONBOARD THESE DAYS – not only due to AIR RAGE

 

Panic onboard – That is what happened on a JetBlue aircraft last week. The captain dashed to the bathroom’s door which was locked, got jittery, then running along the aisle, he hollered out insane things such as « They’re going to take us down! ». The passengers wrestled the pilot down, tied him up with seat belts, and he was handed over to the police after landing.

An incident of this kind had already been reported two weeks before. An American Airlines flight attendant had been giving the safety instructions just before takeoff. She suddenly ranted about mechanical issues which were immediately refuted by the other cabin crew members. She kept speaking incoherently about Al-Qaeda, and the 9/11 attacks, about her fears of crashing, etc. A few people managed to wrestle her down, and the passengers were startled and scared as they could hear her blood-curdling screams when she was being handcuffed by the police.

According to these reports, these insane behaviors are believed to be air-rage cases but the flight attendant who got temporarily mad would be deemed bipolar by doctors, and her condition could explain her behavior. As far as the JetBlue pilot is concerned, his neighbors cannot understand as they would see him as a kind person.

Another scary situations occurred in flight this week on Monday April 2, 2012. 80-year-old Helen Collins landed the Cessna 414 twin-engine aircraft in which the pilot – her husband – died a few minutes before at the controls!

Thanks to the video/audio tape hereafter, we can imagine now what was going through her mind as it was the first time she had flown an aeroplane: (video with transcripts – click on the link below)

http://youtu.be/QxZKKDTRgyk

Outstanding Helen Collins hurt her back, and cracked a rib but she managed to bring the plane to a safe stop at Door County Cherryland Airport, near Sturgeon Bay, Wisconsin.

Last but not least, HATS OFF to Braden Blennerhassett, an Australian pilot who never panicked last Tuesday as a SNAKE popped out from the dashboard; slithered down his leg while he was landing! Read the SCRIPT and listen to the video link about this story below:

 

Here is how this brave pilot kept his cool on his aircraft (interview):

 

Another interesting video with the air traffic controller about the emergency message she received:

http://www.dailymail.co.uk/news/article-2125423/Snakes-Plane-Reptile-cockpit-forces-Darwin-pilot-make-emergency-landing.html

These recent stories – not to mention the latest crash of an F/A-18D Hornet from Naval Air Station Oceana, Virginia, on Friday in which the pilots managed to bail out safely before the fighter aircraft crashed into an apartment building fortunately left with no death toll – remind us of this well-worn saying: Flying is simply hours of boredom punctuated by moments of stark terror.

Special thanks to Xavier Cotton – Passion pour l’aviation‘s webmaster – for his help and support, and for passing these video links on to me. Thank you very much indeed. 😉

 

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SKYDIVER TO BREAK NEW FREE FALL RECORD

 

Felix Baumgartner, an Austrian skydiver, performed a challenging test jump on Thursday March 15, 2012.

Felix Baumgartner has the right stuff. He is a well known BASE jumper. B.A.S.E. means Buildings; Aerials; Spans (jumps from bridges); and Earth (jumps from cliffs). He performed numerous stunts such as jumping from the Petronas Towers in Kuala Lumpur, the statue of Christ the Redeemer in Rio de Janeiro, World Financial Center T101 in Taipei, and the Millau viaduct.

Yesterday’s jump test is just a stage in his attempt to break a new free-fall record. He jumped above Roswell, New Mexico at an altitude of 71,581 feet ie 21.8 kilometers; 13.6 miles; or Flight Level 716. He should then carry out another jump test before leaping again from a capsule lifted by a helium balloon at around 120,000 ft ie 23 miles or 37 km this year, and could become the first man to break the sound barrier while free falling.

 


 

MEDICAL CHALLENGE

This is not a simple leap in the sky. People may not understand how dangerous skydiving at such heights is. The air density is so low that it cannot brake movements as drag becomes poorer up there.

Therefore, a position mistake can make the human body tumble violently or spin very fast. High rotation speeds involve high-G forces due to the centrifugal force, and may lead to G-LOC (G-force induced Loss Of Consciousness), and even to the rupture of blood vessels.

Moreover, if a spacesuit were to leak (due to a dormant seal failure or a cracked/crazed faceplate, for instance), the blood could be boiling (ebullism at 37°C above 63,000 ft or 19 km) because of the very low air pressure, and the body could be swelling, and actually freezing to death as the external temperature can reach down to -70°C, and even lower, not to mention the risk of pulmonary barotrauma.

The current record is held by Joseph Kittinger (a former USAF pilot who is curently advising Felix Baumgartner on his project) who jumped from 102,800 feet in 1960. He temporarily lost the use of his hand which got twice as big as a glove seal was leaking during the final part of the ascent. With this test jump, Felix Baumgartner already belongs to the highest three skydivers along with Joe Kittinger, and Russian Eugene Andreev who performed the longest parachute jump from 83,523 feet (25.5 km).

The following video shows that this feat is not only a matter of pushing limits as researchers are working on this Red Bull Stratos project to prepare flight safety of the future spacecraft:

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Could RAFALE benefit from F-35 glitches?

 

JSF F-35 Lightning II
F-35 Lightning II

The British Harriers were to be replaced by the F-35Cs. Do you remember? You may have learnt from the recent news that the carrier variant of the Lockheed Martin Aeronautics Joint Strike Fighter – CV JSF (Carrier Vessel variant’s Joint Strike Fighter) – F-35C was unable to catch the wire onboard the aircraft carrier during the latest landing tests.

Strange as it may seem, the F-35C’s designers may have not forecast what would unfold during a test flight while landing on an aircraft carrier:

The arresting hook (tailhook) never engaged the arresting wire as the clearance between the tail hook and the main landing gear’s tyre tread is too short for such a speed. An F-35C Lightning II missing her carrier landing has been reported even though some U.S. officials would have dismissed such information which might result from simulated tests.

Added to that is a software bug which had grounded the CV JSF for 6 days a few month earlier for the fifth-generation fighter aircraft might have encountered wing-folding input while flying!

As a result, the British Ministry of Defence might find a Plan-B solution as these design flaws, and some others which date back to November 2011 are deemed unacceptable for such an expensive fighter aircraft – $139.5 million for the F-35C (CATOBAR – Catapult Assisted Take Off But Arrested Recovery), and $150 million for the F-35B (STOVL – Short Take-Off and Vertical Landing). The latter can land on carriers but she is more expensive, and the JSF program costs have already increased several times.

 

Moreover, the JSF would not be able to fire AMRAAM air-to-air missiles as reported in this video:

 

 

RAFALE La Ferté Alais 2010 - © Xavier Cotton http://passiondesavions.blogspot.de/
RAFALE La Ferté Alais 2010 © Xavier Cotton http://passiondesavions.blogspot.de/

And there’s even more: according to a Pentagon study team report, 13 areas of concern that remained to be addressed in the F-35 would have been identified. For instance, the Helmet Mounted Display System (HMDS) would not work properly…

The British MoD is therefore considering the purchase of either F/A-18E Super Hornets or RAFALEs for the RAF. The French Dassault which has already lost the Swiss NAC tender due to replace the Swiss Air Force’s F-5s, would be proposing a new offer with 18 RAFALEs at a cost deemed lower than the 22 SAAB Gripens’ one according to the Swiss press.

The RAFALE is still in competition with the Eurofighter in the Indian MMRCA tender. the Indian officials are expected to make a decision this week. To be continued… ==> We have just learnt (on January 31, 2012) that the RAFALE has won the MMRCA tender… 🙂

 

Photo 1: © Recce 233 Savoie; Photo 2: © Xavier Cotton – http://passiondesavions.blogspot.de/

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