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Fuselage hole forces emergency landing by Southwest flight from Phoenix to Sacramento

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XiaNaphryz

LATIN, MATRIPEDICABUS, DO YOU SPEAK IT
http://www.sfgate.com/cgi-bin/article.cgi?f=/n/a/2011/04/01/state/n205845D63.DTL&ao=all

(04-02) 12:21 PDT PHOENIX, AZ (AP) -- Flight attendants had begun to take drink orders when the explosion rocked the cabin.

Aboard Southwest Flight 812, Shawna Malvini Redden covered her ears, then felt a brisk wind rush by. Oxygen masks fell, the cabin lost pressure and Redden, now suddenly lightheaded, fumbled to maneuver the mask in place.

Then she prayed. And, instinctively, reached out to the stranger seated next to her in Row 8 as the pilot of the damaged aircraft began a rapid descent from some 34,400 feet in the sky.

"I don't know this dude but I was like, 'I'm going to just hold your hand,'" Redden, a 28-year-old doctoral student at Arizona State University, recalled Saturday, a day after her Phoenix-to-Sacramento flight was forced into an emergency landing at a military base in Yuma, Ariz., with a gaping hole in its fuselage.

No serious injuries were reported among the 118 people aboard , according to Southwest officials.

What caused the part of the fuselage to rupture on the 15-year-old Boeing 737-300 was a mystery, and investigators from the National Transportation Safety Board arrived in Yuma on Saturday morning to begin an inquiry.

Southwest, meanwhile, grounded about 80 similar planes in its fleet for inspections, and said that some 300 flights likely would be canceled Saturday because of the reduced fleet.

Southwest operates about 170 of the 737-300s in its fleet of about 540 planes, but it replaced the aluminum skin on many of the 300s in recent years, spokeswoman Linda Rutherford said. The planes that were grounded Saturday have not had their skin replaced, she said.


"Obviously we're dealing with a skin issue, and we believe that these 80 airplanes are covered by a set of (federal safety rules) that make them candidates to do this additional inspection that Boeing is devising for us," Rutherford said.

Julie O'Donnell, an aviation safety spokeswoman for Seattle-based Boeing Commercial Airplanes, confirmed "a hole in the fuselage and a depressurization event" in the latest incident but declined to speculate on what caused it.

There are a total of 288 Boeing 737-300s currently operating in the U.S. fleet, and 931 operate worldwide, according to the Federal Aviation Administration. "The FAA is working closely with the NTSB, Southwest Airlines and Boeing to determine what actions may be necessary," the FAA said in a statement released Saturday.

Southwest officials said the Arizona plane had undergone all inspections required by the FAA. They said the plane was given a routine inspection on Tuesday and underwent its last so-called heavy check, a more costly and extensive overhaul, in March 2010.


The 737-300 is the oldest plane in Southwest's fleet, and the company is retiring 300s as it take deliveries of new Boeing 737-700s and, beginning next year, 737-800s. But the process of replacing all the 300s could take years.

Seated one row from the rupture, Don Nelson said it took about four noisy minutes for the plane to dip to less than 10,000 feet. "You could tell there was an oxygen deficiency," he said.

"People were dropping," said Christine Ziegler, a 44-year-old project manager from Sacramento who watched as the crew member and a passenger nearby fainted. Nelson and Ziegler spoke after a substitute flight took them on to Sacramento.

Brenda Reese described the hole as "at the top of the plane, right up above where you store your luggage."

"The panel's not completely off," she told The Associated Press. "It's like ripped down, but you can see completely outside... When you look up through the panel, you can see the sky."


Cellphone photographs provided by Reese showed a panel hanging open in a section above the plane's middle aisle.

At an altitude of over 34,000 feet, the Southwest pilots would have had only 10 to 20 seconds of "useful consciousness" to get their oxygen masks on or pass out, said John Gadzinski, an airline pilot and aviation safety consultant.

"The higher you are the less useful consciousness time you have," said Gadzinski, president of Four Winds Consulting in Virginia Beach, Va. "It's a credit to the pilots that they responded so quickly."

A loss of cabin pressure just after takeoff knocked out the pilots of a Helios Airways Boeing 737 in August 2005. The plane flew into a hillside north of Athens in Greece, killing all 121 people aboard. In that case, an investigation found the pilots had failed to heed a warning that the pressurization system wasn't working correctly.

In this case, the hole and subsequent depressurization wouldn't have affected the pilots' ability to control the plane as long as they had their oxygen masks on, Gadzinski said.

"The fact that you have a breach hole doesn't affect the aerodynamics of the plane. The plane still flies exactly the same," he said.

A similar incident happened in July 2009 when a football-sized hole opened up in flight in the fuselage of another Southwest 737, depressurizing the cabin. The plane made an emergency landing in Charleston, W.Va. It was later determined that the hole was caused by metal fatigue.

Afterward, Southwest and the FAA reached an agreement specifying actions the airline would take to prevent another episode, said John Goglia, a former National Transportation Safety Board member and an expert on airline maintenance. The details of that agreement are considered proprietary and haven't been made public, he said.

The latest incident "certainly makes me think there is something wrong with the maintenance system at Southwest and it makes me think there is something wrong with the (FAA) principal maintenance inspector down there that after that big event they weren't watching this more closely," Goglia said in an interview.

There was "never any danger that the plane would fall out of the sky," Goglia said. "However, anybody on that airplane with any sort of respiratory problems certainly was at risk."

Four months before that emergency landing, the Dallas-based airline had agreed to pay $7.5 million to settle charges that it operated planes that had missed required safety inspections for cracks in the fuselage. The airline, which flies Boeing 737s, inspected nearly 200 of its planes back then, found no cracks and put them back in the sky.


In 1988, cracks caused part of the roof of an Aloha Airlines Boeing 737 to peel open while the jet flew from Hilo to Honolulu. A flight attendant was sucked out of the plane and plunged to her death, and dozens of passengers were injured.

Three years ago, an exploding oxygen cylinder ripped a gaping hole the fuselage of a Qantas Boeing 747-438 carrying 365 people. The plane descended thousands of feet with the loss of cabin pressure and flew about 300 miles to Manila, where it made a successful emergency landing. No one was injured.

As for Friday's flight, there was obvious relief when it touched down safely. And when the pilot emerged after the landing, the atmosphere turned celebratory, Redden said.

"When the pilot came out a little bit later to look at the damage, we clapped and cheered. If overhead bins weren't in the way, I'm pretty sure we would've given him a standing ovation," she said.

a291853b-256e-4fd6-9598-e63301f04f58.jpg


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The main concern with skin issues is that it may cause explosive decompression and then something like Aloha Airlines Flight 243 may be repeated which was also a Boeing 737, albeit an older design:

Around 13:48, as the aircraft reached its normal flight altitude of 24,000 feet (7,300 m) about 23 nautical miles (43 km) south-southeast of Kahului, a small section on the left side of the roof ruptured. The resulting explosive decompression tore off a large section of the roof, consisting of the entire top half of the aircraft skin extending from just behind the cockpit to the fore-wing area.[2]

As part of the design of the 737, stress may be alleviated by controlled area breakaway zones. The intent was to provide controlled depressurization that would maintain the integrity of the fuselage structure. The age of the plane and the condition of the fuselage (that had corroded and was stressing the rivets beyond their designed capacity) appear to have conspired to render the design a part of the problem; when that first controlled area broke away, according to the small rupture theory, the rapid sequence of events resulted in the failure sequence. This has been referred to as a zipper effect.

First Officer Madeline "Mimi" Tompkins' head was jerked back during the decompression, and she saw cabin insulation flying around the cockpit. Captain Robert Schornstheimer looked back and saw blue sky where the first class cabin's roof had been. Tompkins immediately contacted Air Traffic Control on Maui to declare mayday, switching duties with Captain Schornstheimer, who from this point on, took over control of the plane, as it is usually customary for the Captain to take over a flight that enters a state of emergency.

At the time of the decompression, the chief flight attendant, Clarabelle "C.B." Lansing, was standing at seat row 5 collecting drink cups from passengers. According to passengers' accounts, Lansing was blown out through a hole in the side of the airplane by the greater air pressure remaining in the cabin.

86e9403a-6425-4504-ba8e-ad34af89b69b.jpg


Aloha_Airlines_Flight_243_fuselage.png
 

esquire

Has waited diligently to think of something to say before making this post
I was on a Southwest flight a few days ago. I don't normally fly Southwest but the first thing I noticed as the plane took off and climbed was how much the cabin creaked and squeaked as it pressurized. I've never noticed that on any other plane 737 or otherwise. To be totally honest, it scared me and I thought something like this would happen on my flight. Their planes are pretty old and they fly them almost 24 hours a day...

Glad the pilots were able to land the plane safely. Hope this problem is taken care of right away because it could've been a lot worse.
 

GaimeGuy

Volunteer Deputy Campaign Director, Obama for America '16
esquire said:
I was on a Southwest flight a few days ago. I don't normally fly Southwest but the first thing I noticed as the plane took off and climbed was how much the cabin creaked and squeaked as it pressurized. I've never noticed that on any other plane 737 or otherwise. To be totally honest, it scared me and I thought something like this would happen on my flight. Their planes are pretty old and they fly them almost 24 hours a day...

Glad the pilots were able to land the plane safely. Hope this problem is taken care of right away because it could've been a lot worse.
If I were you I would inform Southwest and/or the FAA about this, just to help them out in their inspections.

Tell them what route you flew and when, and they'll be able to look up which plane was being used for that flight.
 

Guts Of Thor

Thorax of Odin
esquire said:
I was on a Southwest flight a few days ago. I don't normally fly Southwest but the first thing I noticed as the plane took off and climbed was how much the cabin creaked and squeaked as it pressurized. I've never noticed that on any other plane 737 or otherwise. To be totally honest, it scared me and I thought something like this would happen on my flight. Their planes are pretty old and they fly them almost 24 hours a day...

Glad the pilots were able to land the plane safely. Hope this problem is taken care of right away because it could've been a lot worse.

OP and this post make me VERY uneasy about flying Southwest to Phoenix at the end of this month.
 

XiaNaphryz

LATIN, MATRIPEDICABUS, DO YOU SPEAK IT
Guts Of Thor said:
OP and this post make me VERY uneasy about flying Southwest to Phoenix at the end of this month.
Southwest has grounded all planes of the same model for inspections. If they're still being looked out at the time you fly out, you'll likely be on a newer model plane.
 

esquire

Has waited diligently to think of something to say before making this post
GaimeGuy said:
If I were you I would inform Southwest and/or the FAA about this, just to help them out in their inspections.

Tell them what route you flew and when, and they'll be able to look up which plane was being used for that flight.
Will do. Never thought about it because without this incident to frame the observation, it sounds paranoid.

Don't mean to scare anyone. Flying is very safe. As you can see, even though this happened, the pilots were still able to land the plane successfully. Southwest has an excellent safety record if it's any consolation.
 

Angry Fork

Member
flight_815.jpg


Couldn't find any pictures of an airplane + a sunset heading towards the lost island =(

Glad nothing happened though, that's crazy that such a huge hole is there and nothing happened. Usually in movies when there's a gunshot or something in the plane the whole plane goes crazy and so on, I guess they just make that stuff up for hollywood purposes.
 

GaimeGuy

Volunteer Deputy Campaign Director, Obama for America '16
Guts Of Thor said:
OP and this post make me VERY uneasy about flying Southwest to Phoenix at the end of this month.
You're far safer in the air on a plane than you are on the ground in an automobile.
 

Al-ibn Kermit

Junior Member
I've heard about aluminum having this problem before. A steel fuselage may slowly crack while aluminum just suddenly fails. Of course, it's a lot lighter than steel so it's the only real option.
 

mclaren777

Member
My wife is on a flight to DC as I type this and I'm glad she wasn't flying with Southwest because I'm guessing today's groundings are inconveniencing tons of people.
 

toxicgonzo

Taxes?! Isn't this the line for Metallica?
More like convertible, M I RITE?

But seriously, that is scary and I am glad everybody is ok
 

7aged

Member
esquire said:
I was on a Southwest flight a few days ago. I don't normally fly Southwest but the first thing I noticed as the plane took off and climbed was how much the cabin creaked and squeaked as it pressurized. I've never noticed that on any other plane 737 or otherwise. To be totally honest, it scared me and I thought something like this would happen on my flight. Their planes are pretty old and they fly them almost 24 hours a day...

Glad the pilots were able to land the plane safely. Hope this problem is taken care of right away because it could've been a lot worse.

It's unlikely to do with the pressure vessel. The creaking and squeeking noise you've heard probably came from the interior fittings (overhead bins, sidewalls, dividers etc..) reacting the plane flexing (which is normal).
 

esquire

Has waited diligently to think of something to say before making this post
7aged said:
It's unlikely to do with the pressure vessel. The creaking and squeeking noise you've heard probably came from the interior fittings (overhead bins, sidewalls, dividers etc..) reacting the plane flexing (which is normal).

Maybe. Maybe not. On that specific plane the roof actually rose up once the cabin was pressurized like a balloon becoming fully inflated (LOL). I guess what I'm trying to say is Southwest's planes are really, really old!


On a related note,
http://open.salon.com/blog/bonnie_russell/2011/04/02/southwest_flight_812_-_gerald_sterns_deja_vu

If the original story that this thread is based on didn't scare you this actually will. I never knew Southwest had these exact problems before :\
 

XiaNaphryz

LATIN, MATRIPEDICABUS, DO YOU SPEAK IT
100 more flights cancelled as Southwest continues inspections, cracks found in 3 more jets:

April 4 (Bloomberg) -- Southwest Airlines Co. said it will scrub 100 more flights today and reported "small, subsurface cracks" in two jets during inspections for metal fatigue after a plane's fuselage tore open in flight.

The dropped flights follow 300 cancellations yesterday, or 9 percent of the schedule, said Chris Mainz, a spokesman. Checks on 21 Boeing Co. 737-300 planes found two that needed repair, and 19 others were returned to service, Southwest said. The Associated Press reported cracks were found in three jets.

The April 1 incident on Flight 812 spurred checks of 79 of Dallas-based Southwest's 737-300s. Airlines must make regular checks of their planes for metal fatigue, which can occur as jets endure the stress of takeoffs, landings and low outside air pressure of high-altitude flight.

"Assuming proper inspections were carried out at the proper intervals, the issue appears to be whether or not the intervals were adequate to catch the rapid propagation of what are reported as 'multisite' fatigue cracks," said Bob Mann, president of consultant R.W. Mann & Co.

Investigators probably also will look at whether the repetitive inspection process "actually contributes to accelerating the propagation of cracks," said Mann, who is based in Port Washington, New York.


Fatigue Cracking

The National Transportation Safety Board said yesterday that the jet showed signs of fatigue cracking near the hole in the hull after it was inspected following an emergency landing in Yuma, Arizona. Flight 812 passengers described the hole as being 1 foot (0.3 meters) wide by 3 feet long, said Linda Rutherford, an airline spokeswoman.

Another spokeswoman, Whitney Eichinger, said today's cancellations would be fewer than the approximately 300 flights scrubbed on each of the past two days because the airline was getting more of the 737-300s back in service.

Southwest is the world's biggest operator of 737s, the world's most widely flown airliner. Its 548-plane fleet consists solely of different models of the 737.

Metal fatigue was blamed for an 18-by-12 inch rip in a Southwest 737 in July 2009 that was flying at 35,000 feet, an incident that also forced an emergency landing. In January 2010, the Federal Aviation Administration ordered fuselage checks for metal fatigue on 135 737-300s, -400s and -500s in the U.S., after Boeing recommended such checks in September 2009.

A Boeing spokesman, Marc Birtel, said no fleetwide action is being taken for the line of 737s. The Chicago-based planemaker is working with Southwest and the NTSB in the investigation, and will take action if there's a need, he said.

The April 1 incident occurred as Flight 812 was bound for Sacramento, California, from Phoenix. A flight attendant and a passenger were injured, said Rutherford, the airline spokeswoman.

The plane will be 15 years old in June; its fuselage skin had been inspected on March 29 and Feb. 5, Rutherford said.

According to the airline's website, it had 171 737-300s as of Dec. 31, 2010. The average age of those aircraft was 19 years as of the end of 2010.

Southwest flight from Oakland to San Diego diverted to Los Angeles due to burning smell:

(04-04) 06:39 PDT LOS ANGELES, CA (AP) --

A Southwest Airlines Boeing 737-300 carrying 142 people diverted to Los Angeles because of a burning electrical smell in the passenger cabin, two days after another Southwest airplane of the same model made an emergency landing in Arizona after a hole was torn in the fuselage ceiling, officials said.


Sunday evening's flight was en route from Oakland, Calif., to San Diego when the pilot made an unscheduled landing at Los Angeles International Airport about 8 p.m. PDT after reporting a mechanical problem, airport spokesman Harold Johnson said.

The passengers continued to San Diego without further incident, arriving about 10 p.m. PDT, Southwest spokeswoman Whitney Eichinger told The Associated Press. No one was injured.

"They swapped aircraft and went on to their destination," she said.

She said the plane is undergoing an inspection to determine the cause of the electrical burning smell, but stressed the problem "was completely unrelated to the issue in Arizona."

Like the Arizona plane, Sunday's aircraft was also a Boeing 737-300. But Eichinger said it wasn't among the 79 planes Boeing grounded for inspections following Friday's emergency landing. She said the inspections weren't required for the aircraft because it was manufactured differently, but she didn't elaborate.


On Friday, a 5-foot-long hole tore open in the passenger cabin roof area of a Southwest 737-300 shortly after it left Phoenix for Sacramento, Calif.

None of the 118 people aboard was seriously hurt as the plane descended from 34,400 feet to a military base in Yuma, 150 miles southwest of Phoenix.

Since then Southwest ordered the groundings and has begun the inspections.

Officials reported Sunday that three more of the planes have small, subsurface cracks that are similar to the cracks suspected of playing a role in the Friday's fuselage tear.
 
This is scary and all and I worry about Southwest plane's safety but I still cling to the fact that no Southwest planes has never killed any passengers and crew. The only person killed by a Southwest plane involved being the 6 year old boy being in a vehicle on the ground.

I hope it continues that way.
 
Guess what guys?

http://www.nola.com/news/index.ssf/2011/04/united_airlines_flight_makes_e.html

United Airlines flight makes emergency landing at Armstrong International
By Danny Monteverde, The Times-Picayune

A United Airlines flight that left Louis Armstrong International Airport Monday morning was forced to turn around and make an emergency landing minutes after takeoff when smoke was reported in the cockpit, an airport spokeswoman said.

The San Francisco-bound flight was forced to land a short time after it took off. The flight took off at 7:07 a.m. and landed at 7:20 a.m.

The aircraft's front wheel was stuck in mud at the 2,000-foot mark after it partially veered off the 7,000-foot runway during its landing. Wilcut said passengers reported that the pilot said he was having trouble with the aircraft's maneuverability shortly before the landing.
Copilot Ronald Lee Young told an Associated Press reporter aboard the Airbus 319 that he landed on backup systems, with minimal steering and braking ability, after the plane lost all electronics.

"When things start to go wrong, there's always a system ... we can go back to," he said.
He said the plane, heavy with fuel for the cross-country flight, ran off the runway and blew a tire.

As soon as the plane was on the ground, flight attendants shouted "Leave everything. Get out!" Passengers slid down the front and back slides.

A few passengers walked to an ambulance after a call for anyone with injuries. The injuries appeared to be minor, such as abrasions from the slide.

Online records from the Federal Aviation Administration show the plane was built in 1994.
Crews remained on the scene of the landing Monday morning and began to unload passengers' luggage. Meanwhile, other flights taking off flew over the United aircraft at the end of the runway.

United Airlines has set up a "family center," where passengers can claim their luggage and decide if they'd like to continue with their travel plans.

Wilcut said the airport's east-west runway was scheduled to be closed today for construction work, but that it has been reopened while crews work to move the United aircraft from the north-south runway. Wilcut said the airport can operate with only one runway, and she did not expect any delays for other scheduled flights.

United will be in charge of moving the aircraft off the runway. The airline and the National Transportation Safety Board will investigate what caused the smoke, Wilcut said.

Not a good time to fly it seems.
 
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