IASA SUMMARIES fire/Smoke

IASA STUDY OF 270 WIRE-RELATED ACCIDENTS/INCIDENTS

LAST REVISED. 3/2/2001 by jking1@mediaone.net. IASA Data Specialist

Introduction

The following is a chronological list and brief summaries to aircraft “Wire” related events including significant systems failures, smoke and or fires. Some industry actions have also been added. This list is by no means intended to represent all such events known but rather is an attempt to focus more clearly on those where wire or wire types become known. Other IASA studies are available that broaden these number of events where “electrical” becomes the focus rather than just those where the word “wire” is more easily recognized. 109 additional such items to the 270 here may be found on page 14.

Identifying the various wire types or that the wires themselves have become directly causal is difficult because of the absence of such fault coding in the ATA coding system used throughout the commercial industry. The industry has now recognized this diminishing factor and recognized by the military some years ago.

Sources

The vast majority of events seen here come from the databases of the FAA’s Office Of System Safety which include;

The FAA Incident Data Reporting System

Aviation Safety Reporting System (ASRS)

NTSB Accident/Incident Reports

NTSB Recommendation Reports

NTSB Monthly Reports

And miscellaneous FAA Tech Reports/Letters

The URL source references and a guild to access them may be found at the back of this report. Also many other source URLs have been incorporated into the event description where economy of space allowed.

1.August 18, 1972 Lockheed L-1011. First recorded arc-tracking/arc-over event in commercial aircraft. 7 wires severed. Lockheed Report # 10 1973.

2. 6/30/77. TWA (W.B. Clark) objects to Boeing’s continued use of Kapton wiring.

3.5/27/83. L-1011, TWA. Flight 111, Smoke and flames in the cockpit. Kapton wire damage. NTSB Accident/Incident Report # MKC83IA116.

4 6/2/83. DC-9-32. Air Canada. Near Cincinnati experienced an inflight fire and an Emergency landing at Cincinnati. Lav pumps, associated wiring and deterioration of wire insulation were inspected. NTSB Monthly Report # DCA83AA028.

5. 9/2/83. TWA acknowledges over 30 instances with Kapton wiring failures. Report 1702.

6 5/17/84. DC-10, Northwest Airlines. During climb saw sparks and smoke from the left side panel under his glare shield. Flight returned, and wire-bundle insulation and fabric sleeve around wire-bundle were found burned. Circuit breakers were tested, no cause found as to why they failed to open. NTSB Accident/Incident Report # CHI84IA196

7.4/6/84. FAA acknowledges considerable adverse experience with Kapton wiring among several operators, stating an investigation is warranted. States problem is under-reported. Memorandum FAA’s Leroy Keith to all managers of ACOs.

8. 1/14/85. 757, Monarch Airlines. Loss of left generator due to flashover of Kapton feeder cables and lavatory leak. See 1/26/89 FAA/ Congressman Dingell letter and AD 85-12-08.

9. 5/10/85. Monarch Airlines 757. Kapton power feeders chafe and arc. Wire-bundle vaporized. Adjacent wire-bundles damaged. Boeing Alert Service Bulletin 757-24A0025.

10. 9/19/85. 727, Braniff Airlines. On landing noticed sparks from C/B Panel. Replaced wires, C/Bs, current sensing coils. FAA Incident Rpt # 19850919051729C.

11.10/18/85. L-1011,Royal Jordanian Airlines in-flight fire. Kapton wires arced and ignited a titanium air-duct. NTSB Recommendations Rpt # A-85-91.

13.7/12/87. Delta 767-232, Kapton wiring harness causes uncommanded go-around malfunction. NTSB Monthly, Ref http://www.ntsb.gov/aviation/NYC/87A202.htm.

14.3/88. DC-10, Northwest Airlines. Fire in electrical compartment, arcing cables, flames 1 to 2 feet high from ignited insulation blankets. Ref. DOT/FAA/CT-91/2 TechRpt.

15. 2/24/89. 747, United flight 811. Faulty Wiring and/or switch cause door to open in-flight. Nine passengers lost. NTSB Rpt. # AAR-92/02. (superceded Rpt. # 90/01).

16.12/30/89. 737, America West. Fire in wheel well due to arcing wire against a hydraulic line. All hydraulics lost. Overran runway. NTSB Monthly Rpt. # LAX90FA061.

17.1/18/90. MD-80, U.S. Air. Overheated wire insulation filled cockpit with smoke. Loose generator terminals found, no cause to cockpit smoke. Ref. DOT/FAA/CT-TN94/55.

18. 5/11/90. 737, Phillipine Airlines. Shortly after pushback aircraft exploded. 8 dead. Wiring caused explosion of center fuel tank. Ref. NTSB Rpt A-90-103. http://www.asy.faa.gov/asp/asy_searchus.asp Type in “A-90-103”

19. 3/17/91. L-1011, Delta Airlines. Flames from the base of the cabin sidewall. Wires burned, 5 C/Bs tripped. Diverted to Goose Bay, Canada. Ref. DOT/FAA/CT-TN94/55.

20. 8/2/91. 737, U.S. Air. While at cruise, lavatory smoke detectors activated and crew smelled smoke but stopped when C/Bs were pulled. FAA Incident # 199108020441799C.

21. 9/28/91. MD-82, Continental Airlines. While taxing smoke came out of the instrument panel. Emergency evac. NTSB Monthly Rpt. # NYC91LA247 and ASRS Rpt. 190436.

22. 9/11. ASRS Pilot Report (de-identified). Cabin reported light bulb pop and cabin crew saw smoke .Electrical fire behind light panel. Flight diverted. ASRS Rpt. # 190451.

23. 10/91. ASRS Pilot Report (de-identified). On climb out smoke reported in cabin. Returned and fire department called. ASRS Rpt. # 190756.

24. 11/13/91. DC-8, Flagfship Express. Cargo door opened in flight. Damaged wires found in a wire-bundle. NTSB Accident/Incident Rpt. # NYC92IA030.

25. 12/91. ASRS PILOT Report (de-identified). On climb-out attendant reported smoke in the cabin. Returned flight. ASRS Rpt.197455.

26. 2/12/91. Evergreen 747-100 experiences in-flight upset and lost 10,000 ft approaching supersonic speeds. Spurious signals caused uncommanded inputs to the autopilot. Poly-X wiring known for spurious signal generation to autopilots. Ref. TSB Report and NTSB Log # 2359, 4/30/92.

27. 1/3/92. 737, United Airlines. Noticed electrical burning odor. Loud arc then heard with flames from aft cockpit panel. Short in a large wire-bundle. NTSB Rpt. # DEN92IA025.

28. 3/92. ASRS Pilot Report. Smoke in cabin and return to gate. During next flight smoke re- occurred. Emergency return. This was the 5 th time in one month. ASRS Rpt. # 206023.

29. 6/20/92. DC-8, Hawaiian Airlines. On ground, smoke from C/B Panel with spiking fire. Used fire extinguisher. FAA Incident Rpt. # 19920620024179C.

30. 6/92. ASRS Pilot Report (de-identified). Cabin declared a fire odor and ceiling was hot. Diverted and declared a emergency. ASRS Rpt. # 214032.

31. 7/22/92. 727, Northwest Airlines. Smoke in the cockpit, diverted to Fort Wayne. Found burned wiring above co-pilots upper window. FAA Incident Rpt.# 19920722033979C.

32. 7/92. ASRS Pilot Report (de-identified). Crew noted sparks, arcing and smoke half way back left side. C/B popped, fire stopped. FAA made 2 inquires. ASRS Rpt. # 214781.

33. 9/92.ASRS Pilot Report (de-identified). At gate, smoke became thicker from behind attendant jump seat with power off. Fire dept called. ASRS Rpt. # 220716.

34. 1/93. ASRS Pilot Report (de-identified). While descending smoke came from C/B Panel behind captain. Emergency divert to BFL, evacuation on runway. ASRS Rpt. # 231385.

35. 5/10/93. MD-11F. # 3 Engine surges with autopilot on or off because of broken wire. Unscheduled landing. Ref FAA SDR 1993051700120. (item 3).

36. 8/6/93. MD-11F. Precautionary shutdown # 2 engine. Replaced # 2 engine wiring cable. Cable assy failed. Ref FAA SDR 1993081100261. (item 4).

37. 9/93. ASRS Pilot Report (de-identified). At post flight, smoke in the cabin. Emergency evacuation. Claimed FAA follow-up-(Incident Data not found). ASRS Rpt.# 251342.

38. 10/8/93. MD-11. Lost ground spoilers. During inspection found numerous burned and chafed wires in the fwd avionics bay. Ref FAA SDR 1993111000022. (item 5).

39. 10/16/93. MD-81, Swissair. Heavy smoke from overhead panel after departing Munich. Emergency landing. Ref. NTSB Recommendation Rpts A-94-136 & A-94-133. German Investigations Unit identified a faulty Emergency Power switch.

40. 11/2/93. MD-11. FADEC fault, return to Block. Suspect “spurious digital signal”. Unable to duplicate. Ref FAA SDR 1993121300179. (item 6).

41. 11/4/93. MD-87, Scandinavian Airlines. On landing crew noticed smoke in aft end. At the gate a fire erupted and extensively damaged the aircraft as arcing Kapton wires ignited flammable Mylar insulation blankets. Danish AAIB Rep # 2/96, SE-DIB.

42. 4/11/94. A-320, Northwest Airlines. From cruise electrical wire insulation burning smell in cockpit. Diverted to Buffalo, replaced fan. FAA Incident Rpt. # 19940411012399C.

43. 11/10/94. 737, China Airlines. After landing ground crew detected burning smell. Opened E/E bay and noted insulation blanket on fire under rack 2. Improper clamping allowed arcing Kapton wires to ignite flammable insulation blankets. Ref. FAA DOT/FAA/AR-97/58. Also see CAAC letter(7/24/96) to the FAA.

44. 10/94. ASRS Pilot Report (de-identified). During cruise C/B Panel (P-18) behind captain emited heavy smoke. C/B popped, smoke stopped. Emergency, diverted. ASRS #285007.

45. 11/94 ASRS Pilot Report (de-identified). Departed LAX, aft cabin filled with smoke. Declared emergency, diverted. Met by FAA.. ASRS Rpt. # 288297.

46. 11/94. ASRS Pilot report (de-identified). MD-80 aborted TO at O’Hare due to smoke/fumes in the cockpit and cabin.

47. 12/8/94. Boeing 767 operator reports worn Kapton wires causing loss of passenger oxygen deployment, emergency lights, passenger signs, emergency evacuation signal and the fuel shutoff for the engine fire-handle switch. Ref. Boeing SB 767-35A0029.

48. 1/8/95. MD-11F. Gear warning on climb out. Unscheduled landing. Found bad wire insulation to position indicator. Ref FAA SDR 1995011300722. (item 9).

49. 1/11/95. DC-9, Columbian aircraft impacted the sea. 52 lost. Sparks and fire seen. Was first delayed because of electrical work. NTSB Monthly Rpt. # DCA95RA013.

50. 2/19/95. MD-11. Found galley power feeder wires arcing to L-3 door stop. (AD 98-25-11 addressed this 34 months later Ref FAA SDR 1995022400481. (item 11).

51. 4/28/95. DC-10. Auto-pilot pitching violently, other deferred. Unscheduled landing. Same AGAIN on 4/29. Found shorts via pins 38-39 and for left outboard elevator. Ref FAA SDRs 1995060200120 and 1995060200121. (items 6 & 7).

52. 4/29/95. MD-11. # 1 AC Buss Tie lock out, Return to gate. Wire # 3-16BL shorted to ground. Ref FAA SDR 19950551900452. (item 12).

53. 5/95. ASRS Pilot Report (de-identified). Smoke in the cabin. Procedures did not stop smoke. Failure of Flap Indication and thrust reversers. FAA met A/C. ASRS # 305701.

54. 5/10/95. 767. During layover found smoke in forward cabin from three shorted wires inside seat track 1C, 2C. Ref FAA SDR 1995051900313. (item 8).

55. 5/17/95. 767. Lost right generator, unable to start APU. Unscheduled landing. Found short in IDG feeder. Ref FAA SDR 1995051900507. (item 10).

56. 5/19/95. DC-10. C/Bs popped, lost # 1 and 2 generators. Unscheduled landing. Found burnt out wire-bundle in forward cargo ceiling. Ref FAA SDR 1995072100418. (item 9).

57. 7/7/95. MD-11. Inspection found arcing and burning off of the pins in the automatic control PCU located in the recess of the Tail Fuel Tank. Concern is the proximity of this Fuel tank. Suspect faulty materials/ sealing. Ref FAA SDR 1995080400534. (item 13).

58. 8/18/95. 767. During cruise found wire-bundle arcing along sidewall, seats 2A &3A. Activated a fire extinguisher. Ref FAA SDR 1995082500003. (item 20).

59. 8/6/95. MD-11, China Airlines. At gate, smoke came from E&E bay. Arcing Kapton wires ignited flammable Mylar batts. Ref. DOT/FAA/AR-97/58 & CAAC /FAA letter.

60. 9/8/95. DC-10. A false warning to high engine oil temperature with engine shutdown and unscheduled landing. A bad wire to ground was found. Ref FAA SDR 1995091500033.

61. 9/95. ASRS Pilot Report (de-identified). During cruise heavy smoke in the cabin. Emergency divert to Nassau. Claimed FAA Investigation. None found. ASRS # 315585.

62. 11/2/95. MD-11. Found on Inspection two engine wire-harnesses chafed. Two incidents; this one -- Ref FAA SDR 1995111300460 And 1995111300461 on 11/6. (items 15,16)

63. 11/13/95. 737, China Airlines. Mylar lnsulation blankets set afire by hot drill chips from maintenance. Ref. DOT/FAA/AR-97/58 and CAAC / FAA Letter 7/24/96 (as above).

64. 11/26/95. MD-82, Atitalia. Prior to TO, fire in the cabin from light ballast spread quickly through ceiling panels, wire-harnesses, insulation blankets. Ref. DOT/FAA/AR-97/58.

65. 11/95. ASRS Pilot Report (de-identified). 737 on taxi-out saw smoke in the cockpit from generator control panel. Third event. FO required medical help. ASRS Rpt. # 321583.

66. 11/95. ASRS Pilot Report (de-identified). MD-88 cabin advised of smoke alarm and odor in the cabin. Smoke in the cockpit. Returned to Atlanta. Cause unknown. ASRS 322428.

67. 11/95. ASRS Pilot Report (de-identified). DC-10 recurring electrical fuel pump failures during fuel dump. Noticed hot electrical smell. Flight returned. ASRS Rpt. # 320312.

68. 1/11/96. MD-11. During cruise had a # 1 engine generator warning. Found shorted and damaged feeder cables in the pylon. Ref FAA SDR 1996011200174. (item 19).

69. 1996 the NTSB declares Air Force One, the President’s aircraft, rewired due to concerns with Kapton wire. Ref. Center Public Integrity Rpt. “In The Unlikely Event”, ISBN1882583-10-8.

70. 1/16/96. 737. During inspection found chafed wire and arcing at E 3-2 Rack. Ref FAA SDR 1996012600172. (item 2).

71. 2/25/96. DC-9. Aborted approach because could not get green gear light. Declared emergency. Faulty wire at switch. Ref FAA SDR 19960301000170. (item 10).

72. 3/2/96. DC-9. A flash and smoke at row 5. Light disconnected due to chafed wires. Light okay. Ref FAA SDR 1996030800123. (item 13).

73. 3/3/96. 737. During climb smoke came from the aft galley area. Unscheduled landing. Found shorted wire. Ref FAA SDR 1996052300102. (item 19).

74. 3/8/96. 747. Leading edge warning during taxi. Found wiring shorted. Return to gate. Ref FAA SDR 1996031500155. (item 4).

75. 3/8/96. DC-9. Smoke while at the gate smoke from overhead near entry. Found burned wiring, scorched insulation. Ref FAA SDR 1996040500468. (item 22).

76. 4/26/96. DC-10. In flight had smell of hot insulation by rows 14 to 18. Could not duplicate. Return to service. Ref FAA SDR 1996050200380. (item 21).

77. 4/28/96. MD-11. Flight arrived with five Avionic C/Bs tripped. Found wire-bundle chafing. Ref FAA SDR 1996060600568. (item 25).

78. 5/3/96. DC-9. At cruise fire annunciator and fire loop illuminated. Found wires W255A16 and 286A16N rubbing together. Ref FAA SDR 1996101000691. (item 41).

79. 5/12/96. DC-9. No green gear light. Diverted to SYR. Replaced left down limit switch wire-harness. Ref FAA SDR 1996062000576. (item 31).

80. 5/31/96. 747. On approach electrical burning smell in cockpit. Taxi light could not be turned off. Shorted witch and wire found. Ref FAA SDR 1996062700585. (item 15).

81. 5/31/96. DC-9. During cruise, smoke in the aft cabin behind F/As seat. Found two burnt wires. Ref FAA SDR 1997010200195. (item 54).

82. 6/1/96. 767. Inspection found numerous C/Bs tripped and chafed wires aft of CHILLER Unit in E/E compartment. Ref FAA SDR 1996061300112. (item 41).

83. 6/5/96. DC-10. During takeoff had slat-disagree lights. Aborted TO. Found chafed wire and replaced sensor to prox box wires. Ref FAA SDR 1996061300092. (item 25).

84. 6/12/96. 747. On climb out had flap lockout. Diverted flight. Found shorted wiring near P54 Panel. Ref FAA SDR 19960620001888. (item 11).

85. 6/15/96. 747. During climb the red light for the nose gear “unsafe” came on. Repaired wire. Ref FAA SDR 1996062700006. (item 12).

86. 6/17/96. DC-9. At the gate, had smoke in the cabin. Light ballast and charred wiring was replaced. Ref FAASDR 1996062000380. (item 30).

87. 6/18/96. 737. On approach anti skid warning came on. Diverted to BWI. Replaced right main gear wire strut harness. Ref FAA SDR 1996071000673. (item 39).

88. 6/23/96. 747. During climb the # 3 hydraulic overheat warning came on. Unscheduled landing. Repaired wire for indication problem. Ref FAA SDR 1996062700179. (item 13).

89. 6/25/96. 767-332ER, Delta Airlines. Wires arced and severed one of two aileron cables. Lost right generator. Emergency landing. Ref. NTSB Monthly Rpt. NYC96IA131. SDR

90. 7/21/96. DC-9. Inspection found the sidewall lights to be flickering. A wire burnt wire-harness was found. Ref FAA SDR 1996072500306. (item 36).

91. 7/22/96. DC-9. Flight attendant reported no power to the forward coffeemaker. Inspection revealed melted wires to a terminal block. Ref FAA SDR 1996080200386. (item 38).

92. 7/26/96. 747, TWA 800. High voltage Poly-X wiring outside the center fuel tank was bundled with the low voltage, split Teflon FQIS wiring inside the tank. A spark/arc transferred this energy into the tank through the wiring. Ref. NTSB AAR-00/03.

93. 7/28/96. 767. During cruise wiring at seats 2A and others shorted and burned through. Ref FAA SDR 1996080200439. (item 52).

94. 7/31/96. 737. Inspection found APU feeder harness and a stringer burnt. Ref FAA SDr 1996080800015. (item 43).

95. 8/5/96. DC-9. At engine start smoke entered the cockpit. Burned wire found at the right heat-exchanger fan. Ref FAA SDR 1996080800520. (item 39).

96. 8/13/96. 737. During cruise, left wing overheat light flickered. Unscheduled landing. Wire found chafed through and shorting. Ref FAA SDR. 1997013000457. (item 96).

97. 8/31/96. 747. During taxi, primary display and C/B tripped. Returned to gate. Repaired chafed wire. Ref FAA SDR 19960905000421. (item 24).

98. 9/3/96. 747. During cruise electrical arc and smoke came from galley work light. Found charred wiring insulation. Ref FAA SDR 1996092600668. (item 27).

99. 10/7/96. 737. During cruise smoke came from behind cockpit overhead panel. Burnt wiring was found. Ref FAA SDR 1996101700002. (item 63).

100. 10/7/96. 737. During takeoff # 2 thrust reverser unlock light came on, aborted takoff. Found chafed wire in pylon area. Ref FAA SDR 19961114000362. (item 72).

101. 10/8/96. MD-11. Inspection found # 2 generator feeder cables chafed over right over wing exit. Ref FAA SDR 1996110100255. (item 28).

102. 10/13/00. DC-9. Inspection found 24 lighting wires burnt, right side, station 1083 to 1205. Ref FAA SDR 1996101700537. (item 43).

103. 11/4/96. DC-9. On approach, aft and forward fuel boost pumps C/Bs tripped. Found wire-bundle chafed in left wing. Ref FAA SDR 1996111400055. (item 47).

104. 11/17/96. 737. Prior to takeoff, sparking, popping and smoke from compass and ignition switch area. Returned to gate. Saw chafed wire. Ref FAA SDR 199611200285. (item 74)

105. 11/23/96. DC-9. During climb, burning odor in cabin. Unscheduled landing. Replaced damaged left ground power wire. Ref FAA SDR 1996121900609. (item 51).

106. 12/10/96. 737. During inspection for ADI malfunction, lav water was found in wire-bundles feeding E/E compart connectors. Ref FAA SDR 1997032700535. (item 125)

107. 12/1196. 757,U.S. Air. Enroute, smoke and fire were visible in the aft floor and side wall area. Emergency and diverted. Examination of the burned area revealed an Audio-entertainment system cable had become shorted. Ref. NTSB Monthly Rpt. CHI97IA041.

108. 12/14/96. 737. During inspection found left wing wire-bundle melted 15 of 32 wires. Ref Boeing service letter 737-SL-24-27. Ref FAA SDR 1996122600319. (item 82).

109. 12/20/96. DC-10. At cruise, C/B for mid cabin reading lights popped. Reset, and burning smell began. Wiring found to be charred. Ref FAA SDR 1996122600432. (item 37).

110. 12/20/96. 737. During climb # 1 engine surged. Declared an emergency and returned. Replaced engine PMC blue harness assembly. Ref FAA SDR 1997012300452. (item 93).

111. 12/27/96. DC-9. After takeoff, right wing fuel boost pump C/B popped, then reset. Aft pump C/B popped, then forward again. Connector arcing, insulation damage in the fuel conduits was noted. Phase C/Bs popped. Ref FAA SDR 1997010200560. (item 55).

112. 1/30/97. Several Boeing 767 Operators report loss of system failure(s) and/or fire due to Kapton wiring chafing on oxygen line fitting which could lead to electrical arcing. Boeing SB 767-35A00229, 6/25/98.

113. 1/14/97. 737. During a inspection, fluid passing through a connector shorted out the rudder Power Control Unit solenoid. Ref FAA SDR 1997030600012. (item 114).

114. 1/15/97. DC-10. During cruise, wing anti ice valves disagree light illuminated and then the # 3 manifold fail light. Found Wire-bundle burned. Ref FAA SDR 1997020600768.

115. 1/20/97. 767. Inspection found strong electrical smell in aft galley. Unable to isolate. Suspect Chiller. Ref FAA SDR 1997013000095. (item 77).

116. 1/20/97. DC-9, Northwest Airlines. Smoke from panel behind captain’s seat. Charred wiring due to phase short and dust particles. NTSB Monthly Rpt. # CHI97IA072.

117. 1/23/97. 767. Inspection found broken wire in cargo hold tripped a C/B. Resetting caused a small fire in the hold and in the insulation. Ref FAA SDR 1997122900005. (item 121).

118. 1/27/97. 737. During cruise, lost series of systems including pressurization. Unable to reset C/Bs, Diverted. # 1 gen wire burnt. Ref FAA SDR 1997020600127. (item 105).

119. 1/27/97. 737. On climb lost radar. Returned to gate. Found shorted Data A Buss B-wire. Ref FAA SDR 1997013000834. (item 104).

120. 3/7/97. 737. While landing had flaps freeze. Found wire between connectors shorted to shield. Ref FAA SDR 1997032700165. (item).

121. 3/8/97. 747. Inspection found # 1 APU generator feeder cables with split insulation and melted spacers. Ref FAA SDR 1997041700153. (item 44).

122. 3/10/97. 737. In cruise, an uncommanded pressurization decent (manual) . Unscheduled landing. Chafed wires near outflow valve. Ref FAA SDR 1997070300284. (item 171).

123. 3/14/97. 737. Sparks under seat 9D. Found shorted wires. Ref FAA SDR 1997032700004. (item 121).

124. 3/14/97. 747. Inspection found chafed wire-harness and a bare wire with signs of arcing at # 1 reserve tank and rib. Ref FAA SDR 1997040300806. (item 43).

125. 3/30/97. DC-9. On climb had fault with right main gear unsafe light. Found high resistance of uplock to terminal wire. Ref FAA SDR 1999041000284. (item 61).

126. 4/24/97. 747. Inspection found # 2 fuel boost pump wiring insulation failed due to conductive corrosion. Ref FAA SDR 1998011500139. (item 72).

127. 4/28/97. 747-243, G-VIRGIN. Arcing Poly-X wires ignite cabin interior materials and destroy wire-bundles behind overhead panels in forward cabin. Ref, UK AAIB Rpt. # 5/2000 (EW/C98/1/3) Appendix G. (www.open.gov.uk/aaib/n653ua/n653ua.htm).

128. 5/9/97. 737. Engine fire warning on touchdown. Fired extinguisher. Found badly chafed fire wire at a clamp. Ref FAA SDR 19970717000869. (item 174).

129. 5/10/97. 737. While at cruise had # 1 transformer rectifier C/B tripping. Unscheduled landing. Found melted wires on C/B. Ref FAA SDR 1997052200816. (item 156).

130. 5/24/97. DC-9. On approach, gear warning light would not go out. Found bare wires and water inside wire conduit. Ref FAA SDR 1997060500660. (item 63).

131. 6/7/97. 737. Smoke and electrical smell near start switch., switch shorted to standby compass. Repaired five wires. Ref FAA SDR 1997 061900262. (item 163).

132. 6/11/97. 747. Smoke and sparks at seat 2EF. Attendant used extinguisher. Repaired failed wiring. Ref FAA SDR 1998021100983. (item 76).

133. 6/17/97. 737. On climb, engine EGT went to 1250 and then blank. Unscheduled landing. Found EGT wires shorted at engine harness. Ref FAA SDR 1997071000062. (item 172).

134. 6/21/97. 767. At cruise had uncommanded IDG disconnect. Wire-harness failed. Ref FAA SDR 1997071700992. (item 95).

135. 6/22/97. DC-9. On taxi out had elevator power fail. Return to gate. Replaced failed wire. Ref FAA SDR 1997072400064. (item 70).

136. 7/3/97. DC-9. At cruise, something electrical is shorting in cockpit overhead panel. Wire shorted. Ref FAA SDR 19970722400519. (item 71).

137. 7/5/97. DC-9, Northwest Airlines. At cruise smoke came from beneath glareshield. Shut off generators, declared emergency. Found burnt wires. NTSB Monthly CHI97IA195.

138. 7/5/97. DC-9. At cruise smoke began filling cockpit from forward panel. Declared emergency. Found 4 feet of burned wires. Ref FAA SDR 1997071000444. (item 67).

139. 7/15/97. DC-10. On climb had high oil temp, shut down # 2 engine. Unscheduled landing. Found shorted wire. Ref FAA SDR 1997081400787. (item 51).

140. 7/28/97. 747. During cruise had sparks/smoke from seat 23-2. Replaced power cable and electronic unit. Ref FAA SDR 1997082100422. (item 58).

141. 8/9/97. 747. On taxi had left wing overheat intermittent light on. Found shorted wire. Ref FAA SDR 1997081400977. (item 57).

142. 8/14/97. DC-9. On approach main gear unsafe light fault. Found several failed wires at terminal block 53-66. Ref FAA SDR 1997100200689. (item 82).

143. 8/25/97. DC-9. While in maintenance check, smoke and wire insulation damage was found near forward entry overhead. Ref FAA SDR 1997082800729. (item 76).

144. 9/6/97. DC-9. On approach had gear warning fault, C/B found popped. Repaired wiring short. Ref FAA SDR 1997091100397. (item 78).

145. 9/12/97. During taxi APU temp panel lights flickering and the smell of smoke in the cockpit. Found burned and chafed wires. Ref FAA SDR 1997091800828. ( item 186).

146. 9/21/97. 747. During climb had wing overheat light. Unscheduled landing. Found chafed wire at clamp. Ref FAA SDR 1997092500774. (item 61).

147. 9/22/97. DC-10. During climb # 2 manifold fail light came on. Unscheduled landing. Replaced wires at manifold loop. Ref FAA SDR 19971000200322. (item 54).

148. 9/25/97. DC-9. During climb had gear fault light. Replaced gear wiring harness and sensor. Ref FAA SDR 19971000200331. (item 81).

149. 9/29/97. 737. During cruise had APU fire warning. Pulled fire handle, light continued. Found wiring out of position. Ref FAA SDR 1997100200721. (item 189).

150. 10/97. ASRS Report (de-identified). During preflight noticed light C/B popped. Sparks and wire arcing and worn insulation found. ASRS Rpt.# 382990.

151. 10/15/97 767. Inspection found generator feeder cable chafed and burned near slat. Ref FAA SDR 1998012200841. (item 125).

152. 11/8/97. 767. During cruise left tank fuel quantity, and totalizer goes blank. Fault code included wiring. Ref FAA SDR 1997120400881. (item 117).

153. 12/8/97. 767. During cruise left generator light flickering. Repairs to T-1 cable to IDG. Ref FAA SDR 1998011500726. (item 124).

154. 12/30/97. 737. During climb unable to control pressurization. Returned to gate. Found C/B tripping, replaced PRSOV wiring. Ref FAA SDR 1998012200253. (item 203).

155. 1/9/98 United Airlines flight 965, 767-322ER, arcing Kapton wires burned Cross-linked Tefzel wiring. Toxic gases emitted, wire-bundles burned. Ref. U.K. AAIB Rpt 5/2000 (EW/C98/1/3), para 1.12.3.8 and 1.18.2. (www.open.gov.uk/aaib/n653ua/n653ua.htm )

156. 1/9/98. 767. During cruise had short circuit in P30 Panel near forward Chiller. Unsched landing. Severe wire-bundle damage. Ref FAA SDR 1998040800005. (item 129).

157. 1/12/98. 737. Inspection found generator feeder cable and loom burnt due to arcing at the plug and socket. Ref FAA SDR 1998111300314. (item 276).

158. 1/13/98. DC-9. On the gate the crew smelled smoke in the cockpit. Found broken wiring causing arcing at audio panel. Ref FAA SDR 199812200236. (item 84).

159. 1/17/98. DC-10. During cruise # 1 start valve light illuminated. Unscheduled landing. Found chafed wiring near valve. Ref FAA SDR 1998012200529. (item 63).

160. 1/18/98. DC-9. On taxi out had acrid electrical odor in cockpit. Light C/B popped. Return to gate. Suspect ballast or wiring. Ref FAA SDR 1998042900488. (item 99).

161. 1/24/98. 737. During cruise a loud popping sound and a spark came out of cockpit overhead. C/B trips. Found shorted wire. Ref FAA SDR 1998031200994. (item 215).

162. 1/25/98. 737. During cruise had engine fire faults. Reoccurring problem. Unscheduled landing. Engine core wiring harness faulted. Ref FAA SDR 1998022600675. (item 213).

163. 6/27/98. 767. NTSB issues recommendations to the FAA on the Kapton wires on 767s due to the risk of in-flight fires or loss of control. The Kapton wires caused electricity to jump to control cables controlling the flight control surfaces. Ref A-98-1/2. (CNN 1/27).

164. 1/29/98. DC-9. While at the gate smoke began coming in from battery compartment. Found broken wire. Ref FAA SDR 1998042900699 (item 100)..

165. 3/1/98. Boeing declares arcing?sparking Kapton should be replaced with cross-linked Tefzel wire. Boeing Flight Summary Report 747-SRP-23-0057.

166. 2/3/98. 767. During cruise flaps indicator jumps, also fault lights illuminated. Rewired at sensors and to wing root. Ref FAA SDR 1998043000009. (item 140).

167. 2/6/98. 737. On climb gear would not raise. Unscheduled landing. Repaired wiring at gear logic shelf E11. Ref FAA SDR 1998031200971. (item 214).

168. 2/8/98. DC-9. During decent had smoke in the cabin. Declared emergency. Repaired wire ends at S3-94. Ref FAA SDR 1998021900305. (item 87).

169. 3/2/98. DC-9. During cruise a burning smell was detected in the rear cabin. Repaired broken wire at wire-bundle for lighting. Ref FAA SDR 1998043000771. (item 101).

170. 3/6/98. 747. During cruise # 4 engine CSD over-temperature. Could Not Disconnect ! No cause found. Solder melted at disconnect. Ref FAA SDR 1998041701129. (item 83).

171. 3/13/98. 747. On taxi out, # 4 engine start valve open light on. Returned to gate. Found wire insulation rotten at engine. Ref FAA SDR 1998032600261. (item 80).

172. 3/15/98. DC-9. During climb the right engine start valve illuminated. Unscheduled landing. Repaired the engine wire-harness. Ref FAA SDR 1998043000860. (item 102).

173. 4/10/98. 767. During cruise had electrical smell and haze at aft right galley. Only Chiller and fridge on. Repaired wiring. Ref FAA SDR 1998082800159. (item 140).

174. 4/17/98. DC-10. Inspection found aft engine power feeder cables shorted at inlet duct panel # 364GR. Ref FAA SDR 199850100056. (item 74).

175. 4/23/98. 737. During cruise # 2 slat transit light illuminated, a previous on 4/16. Unscheduled landing. Wire to be replaced. Ref FAA SDR 1998050100806. (item 230).

176. 4/28/98. 737. Inspection found cockpit overhead wire-bundle chafed and burned. Ref FAA SDR 1998071700469. (item 242).

177. 5/15/98. DC-9. During approach, nose gear downlock warning fault. Declared and emergency. Replaced gear wire-harness. Ref FAA SDR 1998052200834. (item 108).

178. 5/16/98. MD11F. During taxi had # 3 engine vibration warning. Returned to gate. Found engine vibration wire-harness faulting. Ref FAA SDR 1998062000686. (item 45).

179. 5/18/98. UPS 747-123 experiences uncommanded yaw inputs during cruise flight. Found to be a wire problem. Emergency landing. NTSB Monthly CHI98IA164.

180. 5/20/98. DC-9. Inspection found APU power feeder cable shorted on a standoff. Ref FAA SDR 1998052900077. (item 109).

181. 5/30/98. DC-10. After a smoke smell, found decoder harness and wires burnt under seat 22E. Ref FAA SDR 1998060500439.

182. 6/27/98. 737. After take off # 2 generator dropped off line. Could not reset. Unscheduled landing. Replaced generator wire-harness. Ref FAA SDR 1998120400507. (item 284).

183. 6/30/98. DC-9. Nose gear unsafe light illuminated. Replaced electrical harness. Ref FAA SDR 1998072400242. (item 112).

184. 7/15/98. DC-9. During cruise left generator tripped off. Losing hydraulics. Unscheduled landing. Wire arced through a hyd line. Ref FAA SDR 1998082100014. (item 114).

185. 7/22/98. 747. Rejected takeoff due to cargo fire indication. Found chafed wire behind F/Es panel. Ref FAA SDR 1998080700341. (item 104).

186. 8/14/98. 747. On taxi in C/B tripped for lights. Inspection found burnt and overheated wires and arcing. Ref FAA SDR 1998100900902. (item 112).

187. 9/2/98. Swissair 111, MD-11- Investigation still ongoing, but Kapton and Tefzel wiring found that had arced. Mixed wiring types. Probable contributing factors may include incorrect routing/installation of the wiring.

188. 9/24/98. 737. # 1 fuel heat valve came on, oil temp exceeded, shutdown engine. Returned to MCI. Found burned wire at valve. Ref FAA SDR 19981113000986. (item 278).

189. 10/98. ASRS Pilot Report (de-identified). While in cruise, cabin crew noted smell of electrical fire. Diverted to alternate. ASRS Rpt. # 419315.

190. 10/98. ASRS Pilot Report (de-identified). DC-10 dumped 85,000 lbs of fuel, declared emergency and diverted after smelling smoke in the cabin. ASRS Rpt. # 418250.

191. 10/3/98. 767. While in cruise pax spilled drink in electric motor seat and shorted it out. Found chafed shorted wires near floor. Ref FAA SDR 1998100900432. (item 154).

192. 10/8/98. MD-11, Delta Airlines. Two hours West of England enroute to Georgia experienced an electrical odor. Diverted to Ireland. NTSN Monthly # DCA99RA002. Also see FAA SDR 1998101600553; says “burned wiring to compressor” found. Item 51

193. 11/98. L-1011 Kapton wiring arcs in cockpit behind circuit breaker panel. Emergency landing. Aircraft receiving conflicting electrical anomalies. Aircraft thought it was on the ground and in the air at the same time. Ref ASRS AB99:9/3-6

194. 11/8/98. MD-11. Inspection found shorted wire in forward cargo which ignited Mylar insulation blanket. Ref FAA SDR 1998111301330. (item 52).

195. 11/9/98. L-1011 Delta Airlines. Enroute between Honolulu and SFO, electrical fire in the cockpit. Numerous systems were lost. Emergency landing at San Francisco. Previous days had multiple electrical problems. NTSB Rpt. DCA99SA043 & ASRS Rpt. 419799.

196. 11/9/98. DC-9. Inspection found smoke from lower EPC Panel. Found chafed and burned wires near right AC relay. Ref FAA SDR 1998122400289. (item 124).

197. 11/11/98. MD-11. At the gate a fire erupted in the forward cargo hold. Wiring damage led to a Mylar insulation blanket fire. Ref NTSB Recommendation Letter A-99-104 through 106, 12/15/99. See http://www.ntsb.gov/recs/letters/1999/A99_104_106.pdf

198. 11/28/98. 747-400, Quantas Airlines. In flight fire in the E&E Bay. Arcing Kapton wiring ignites flammable insulation blankets. Emergency landing. Ref. NTSB Monthly Rpt. # DCA99WA014 and Ref. AAIB 5/200 (EW/C98/1/3), para 1.18.4 . Item 7.

199. 11/28/98. 747. During climb saw equipment cooling caution. Found damaged and burned wiring & insulation blanket in fwd cargo area. Ref FAA SDR 1998011500351. item 117.

200. 11/30/98. MD-11F. During climb had faults; auto-pilot & throttles, Flt Dir, TAT, flaps, Press, Fan, etc. Returned, found 3 chafed wires. Ref FAA SDR 1998120400240. item 54.

201. 12/25/98. DC-10. During climb had # 1 engine fire warning. Unscheduled landing. Found wire-harness at fault. Ref FAA SDR 1999010100129. (item 90).

202. 12/22/98. L-1011, Delta Airlines. Before pushback, a passenger saw smoke and sparks from a sidewall vent. Two wire-bundles burned in the Mid Electrical Center. Wire to wire arcing, dust buildup and lav fluids were noted. A Delta Report said this was the fifth report of lav water, the eleventh report of wire to wire rubbing, the thirteenth report of excessive dirt buildup among Delta’s 35 L-1011s. NTSB Monthly Rpt. # DCA99WA014.

203. 12/29/98. DC-9. At gate, smoke in the cockpit and cabin. Crew saw an electrical Flash /Fire in comp left of door. Replaced wiring. Ref FAA SDR 1999010800058. (item 125).

204. 1/29/99. 737. Inspection found chafed wires in center fuel tank level switch. Fuel found inside conduit. Ref FAA SDr 1999081200463. (item 357).

205. 1/31/99. MD-11, American Airlines, smoke in the cabin. “Buzz” heard over PA system, C/B reset and then smoke seen in first class. Emergency declared, diverted to Seattle. Video system damaged, unknown connector failure. NTSB Accident Rpt. DCA99SA037

206. 1/99. ASRS Pilot Report (de-identified). During cruise lost all pressurization, smoke in the cabin due to wiring caused electrical smoke. Emergency /divert. ASRS Rpt 424550.

207. 2/13/99. MD-11. Inspection found electrical smell at row 13 and found electrical harness shorted out. Ref FAA SDR 1999021900341. (item 59).

208. 2/16./99. Dc-9. Inspection found left generator feeder cable shorting out in tail cone area. Bulkhead had a hole burned in it. Ref FAA SDR 1999022600217. (item 132).

209. 2/99. ASRS Pilot Report (de-identified). DC-9 got failures of radio fan, GPWS, FDR, # 1 VHF, # 1 VOR, # 3 fuel boost pump, captain’s ADI and CDI. Emergency decent to DTW. At gate, 11 more C/Bs popped.

210. 2/99. ASRS Pilot Report (de-identified). DC-9-30 multiple unrelated electrical failures, most of left system lost but with no auto-transfering. Emergency landing. ASRS 428107.

211. 2/23/99. MD-11. During overnight inspection aircraft would not accept power. Found wire burned and shorted in forward cargo bay. Ref FAA SDR 1999041700401. (item 63).

212. 2/25/99. 737. On landing sparks and smoke in overhead panel behind fuel panel. Several C/Bs popped. Chafed wires behind panel. Ref FAA SDR 1999031200195. (item 327).

213. 2/99. ASRS Pilot Report (de-identified). MD-11 U.S. While parked, a fire in a wire-bundle occurred. 14 wires found brittle and replaced. ASRS Rpt. 431017.

214. 3/5/99. DC-10. Inspection found APU generator feeder cable shorting out at pressure bulkhead. Wire melted. Ref FAA SDR 1999031200607. (item 99).

215. 3/99. ASRS Pilot Report (de-identified). 727 on TO had electrical smoke from the pilot’s overhead panel. Pilot saw burned and charred wiring. ASRS Rpt. 429985.

216. 3/29/99. MD-11, World Airways. During maintenance checks a Kapton wiring harness was found with chafed and arcing damage. Adjacent Mylar blankets also completely burned away. No cause listed. NTSB/Garvey letter, 12/15/99, NTSB Rpt. DCA99SA051.

217. 3/31/99. DC-9. During climb had a loud pop and flash from the EPC C/B Panel, acrid smell. Found chafed power port feeder. Ref FAA SDR 1999043000409. (item 135).

218. 4/9/99. 747. Inspection found # 2 main aft boost pump wiring insulation faulty. Ref FAA SDR 1999070900114. (item 134).

219. 5/3/99. DC-9. During cruise the PSU oxygen masks dropped on the left side. Found wire shorted into forward lav pump under lav. Ref FAA SDR 1999051400001. (item 136).

220. 5/10/99. 747. During inspection found C/B # 152 popped and smoked. Found wire chafing in overhead P5 Panel,wheel well fire Ref FAA SDR 1999061800610. (item 130).

221. 5/16/99. DC-9. Aft left & fwd left fuel boost pump C/Bs popped, later the right side. Declared emergency. Damaged wire-bundle. Ref FAA SDR 1999062500762. (item 142).

222. 5/18/99. 747. Inspection found trailing flap position wire in forward cargo ceiling shorted to ground. Ref FAA SDR 1999070900113. (item 133).

223. 5/21/99. 737. During climb had smoke in the flight deck. Found wire chafed against bracket above P6-1 Panel. Ref FAA SDR 1999060400487. (item 337).

224. 6/20/99. 737. During cruise faults with # 2 fuel gage. Replaced the # 1 and the # 2 wing tank harness assemblies. Ref FAA SDR 1999072300651. (item).

225. 7/7/99. DC-10. Inspection found smoke/sparks in main gear bay. Wiring for # 2 Aux Hydraulic pump burned through but C/Bs not tripped. Ref FAA SDR 1999091000467.

226. 7/8/99. 737. Inspection found 20 damaged wires in the vertical stabilizer and apparently damaged by hydraulic fluid near rudder PCU. Ref FAA SDR 1999081200849. (item 358)

227. 7/27/99. 737. Inspection found system B hydraulic pump line chafing power wire-bundle causing short circuit. Ref FAA SDR 1999112500057. (item 391).

228. 7/27/99. MD-11F. Inspection found forward cargo external power cable arcing below floor and bilge area insulation blanket burnt. Ref FAA SDR 1999073000464. (item 77).

229. 7/31/99. 737. During cruise stabilizer trim actuator C/B pops. Found wires shorted to ground at bulkhead. Ref FAA SDR 1999081200236. (item 356).

230. 8/3/99. MD-11. Inspection found seat 5G electrically inop. Found burned wire. Ref FAA SDR 1999081400461. (item 78).

231. 8/10/99. 737. On takeoff left generator tripped. Smoke in cabin. Unscheduled landing. # 1 TR C/B tripped and generator feeder burnt. Ref FAA SDR 1999082000330. (item 361).

232. 8/24/99. 737. During climb aircraft yawed. Unscheduled landing. Autopilot stabilizer trim wiring found damaged at aft bulkhead. Ref FAA SDR 1999102200599. (item 381).

233. 8/27/99. 737. At climb interphone had ringing chimes, call lights flashing, smoke and flame at 3R Com panel. Wires replaced. Ref FAA SDR 1999102900318. (item 385).

234. 9/2/99. 737. On takeoff # 2 bleed tripped off. Pressurization went to 9,500. Return to block. Wire Open to air bleed regulator. Ref FAA SDR 1999101300025. (item 374).

235. 9/7/99. MD-88, Delta Airlines. During climb noted smoke in the cabin. Emergency and diverted. Mylar insulation burned 5 x 5 foot under floor. No cause. NTSB NYC99IA231. Also reference in NTSB/Garvey letter, 12/15/99 at ntsb.gov/recs/letters/1999/A99_104_106.pdf

236. 9/21/99. MD-11. Inspection found sparks and smoke from under seat 11C. Wire-harness shorted to foot rest. Ref FAA SDR 1999100100110. (item 83).

237. 9/25/99. 737. During climb had uncommanded right and left Yaw. Found a broken wire at forward end of E1 equipment rack. Ref FAA SDR 2000022900039. (item 417).

238. 9/28/99. DC-9. Inspection found SELCAL system wire with burned insulation between station 110 to 160. Ref FAA SDR 1999100100341. (item 153).

239. 10/9/99. 737. En route # 1 and 2 TRs tripped. Reset, tripped again. Electrical smell noted. Unsched landing. Replaced gen feeder harness. Ref FAA SDR 1999110500446. item 389

240. 10/18/99. 737. During climb had smoke in aft galley. Unscheduled landing. Found shorted power wire behind galley. Ref FAA SDR 1999102900119. (item 384).

241. 10/20/99. 737. Aborted takeoff after warning horn sound. Found chafing wire to # 4 SKEW sensor in wheel well. Ref FAA SDR 1999102900116. (item 383).

242. 10/24/99. MD-11. Inspection found chafed and arcing wire at seat 3B, C/B did not pop. Replaced wiring harness. Ref FAA SDR 1999102900893. (item 85).

243. 11/1/99. British 737-500 arcing kapton wiring in E/E bay, wire-bundle found completely charred. Ref . AAIB Rpt. 5/2000 (EW/C98/1/3) Para. 1.18.4.

244. 11/2/99. 737. During climb both fuel flow indicators fluctuated. Unscheduled landing. Found chafed wire near # 1 engine. Ref FAA SDR 1999111100007. (item 390).

245. 11/8/99. DC-10. During climb lost # 2 generator. Reset C/B. Smoke in the aft galley, gen off again. Found feeder wires shorted. Ref FAA SDR 1999111900011. (item 114).

246. 11/9/99. DC-10. Inspection found fuel quantity fault. Wires in aux tank have insulation separation and damage. Ref FAA SDR 19991218000846. (item 119).

247. 11/11/99. 737. During climb multiple C/Bs popped . Unscheduled landing. Found failure of the wire-bundle insulation at BS 410. Aircraft 772 wiring replaced. No system problems found for overload. Ref FAA SDR 1999122300026. (item 399). SEE NEXT.

248. 11/11/99. 737. Alaska Airlines returned after popped C/Bs and low fuel lights. Follow up found additional C/Bs popped and heavily sooted and melted insulation in wiring bundles near cargo hold, station 410. NTSB Accident Rpt. SEA00IA019.

249. 11/19/99. DC-9. During climb generator failed with AC cross lockout. Noted electrical odor. Unshed Landing. Feeder cable shorted. Ref FAA SDR 1999112500233. (item 156).

250. 11/21/99. MD-11. Maintenance found arcing behind seat 13A caused by pinched cable. Ref FAA SDR 1999120400158. (item 88).

251. 12/21/99. DC-10. Number 1 AC Bus C/Bs popping. Found burned wires in ceiling of forward compartment. Ref FAA SDR 1999011500634. (item 92).

252. 1/10/00. 747. Inspection found APU generator feeder cable burned below cabin floor at BS 1450. Ref FAA SDr 2000042800255. (item 165).

253. 1/18/00. DC-10. Inspection found electric hydraulic pump had 2 each shorted wires causing a fire. Ref FAA SDR 2000012900102. (item 122).

254. 1/20/00. 737. During climb had fuel imbalance. Unscheduled landing. Replaced # 1 fuel quantity wire-harness. Ref FAA SDR 2000012000226. (item 407).

255. 1/24/00. 737. During cruise generator tripped off twice. Third time could not reset C/B. Unscheduled landing. Replaced T1 wire. Ref FAA SDR 2000040800132. (item 425).

256. 1/25/00. MD-11. During cruise coffee maker wire burned through but C/Bs did not pop. Ref FAA SDR 2000021200806. (item 91).

257. 1/28/00. 737. While in climb aft lav smoke detector was sounding. Smell in cabin. Unscheduled landing. Found aged lav wire. Ref FAA SDr 2000050300165. (item 429).

258. 1/31/00. 737. During climb fuel quantity indications decreased and erratic. Unscheduled landing. Repaired wires in right wing. Ref FAA SDR 2000022600044. (item 414).

259. 2/2/00. 747. Inspection found generator feeder cable burnt at sta’s 970, 980, and 985. Ref FAA SDR 2000022600048. (item 158).

260. 2/8/00. DC-9. During pushback left pack fan C/Bs tripped. Found heat-exchanger wires chafing and shorted. Ref FAA SDR 2000021900295. (item 168).

261. 2/8/00. 737. During decent # 1 generator Bus off light and systems loss. Declared emergency. Found chafed gen harness. Ref FAA SDR 2000042800409. (item 427).

262. 4/16/00. 737. At climb pressurization fail light illuminated. C/B popped, no control. Wires damaged at controller and aft bulkhead. Ref FAA SDR 2000061000353. item 442.

263. 4/17/00. 737. After liftoff wheel well C/B popped. Had previous repairs to wiring, and now found 20 wires burned at P18-3 panel. Ref FAA SDR 2000060300211. (item 440).

264. 4/18/00. 737. During cruise left wing/body overheat light illuminated. Unscheduled landing. Found chafed shorted wire at APU. Ref FAA SDR 2000061000225. (item 441).

265. 5/1/00. DC-9 On descent had smoke in the cockpit. Found a burnt wire going to map light. Ref FAA SDR 2000062400177. (item 177).

266. 5/20/00.737, Electrical loom (bundle) arcing due to swarf in P6-4 C/B Panel. Overheated power receptacle, cause unknown. Ref . AAIB Rpt. 5/2000 (EW/C98/1/3) Para. 1.18.4.

267. 6/10/00. 747. Inspection found wiring harness arcing at BS 520 in the forward cargo hold. Ref FAA SDr 2000082200021. (item 172).

268. 6/17/00. 737. Inspection found APU wiring melted behind starter connector and burned insulation in the E/E bay. Ref FAA SDR 200072500192. (item 466).

269. 8/8/00. DC-9, Air Tran Airways. Flight returned to Greensboro with very dense smoke in the cockpit. Sparks and smoke seen the area of the forward FA jump seat. Emergency declared. Extensive wire damage in electrical panel behind captain’s seat and blistering of the aircraft skin. Aircraft substantially damaged. NTSB Monthly # DCA00MA079.

270. 10/1/2000, MD-80, Continental Airlines. Kapton arcing burns a fist sized hole in the cockpit. Cockpit filled with smoke. Emergency landing. NTSB Monthly ATL01IA001 and FAA Accident Rpt at http://www.faa.gov/avr/aai/D_1002_N.TXT.

NOTE: This Study is offered in a Word format so that the reader may customize it for areas of particular study. The reader accepts this with the view that any questions to its original content may vary if he is not the original recipient. Reconfirmation may be directed to the editor, John D. King, IASA Data Specialist at jking1@mediaone.net.

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INSTRUCTIONS TO LOCATE SOURCE URSs AND AGENCIES IN THIS IASA STUDY

NTSB Monthly http://www.ntsb.gov/aviation/months.htm Search By Year And Date.

NTSB Recommendations http://nasdac.faa.gov/asp/asy_searchus.asp Search By Report Number.

NTSB Accident/Incident http://nasdac.faa.gov/asp/asy_ntsb.asp Search By Report Number.

FAA Incident Data System http://nasdac.faa.gov/asp/asy_fids.asp Search By Report Number.

Cross System Search to each of the above http://nasdac.faa.gov/asp/asy_crosssys.asp.

ASRS REPORTS At http://nasdac.faa.gov/asp/asy_asrs.asp Search By Report Number.

NASDAC’s Aviation Safety Data Accessibility Study Index http://nasdac.faa.gov/safety_info_study

‘Heinrich Pyramid’ http://nasdac.faa.gov/gain/Presentation/GAIN_Brief.pdf ref page 7 of 42.

If any problems in reaching any of these source documents, please contact the editor, John D. King at jking1@mediaone.net.

MILITARY WIRING ISSUES SEPARATED FROM ABOVE LIST 18 ITEMS

May 1995, Royal Air Force Nimrod, wires arc and fire starts. Aircraft lost.

July 20 1998, Army Command issued to all AH-64 helicopter users to inspect the Kapton wiring which could contribute to uncommanded inputs.

September 4, 1999 NASA’s entire Shuttle fleet grounded for 6 months for Kapton wiring problems.

October 17, 1988, NASA’s Magellan Spacecraft experiences $87,000 electrical fire due to Kapton wiring.

1983 NASA’s Columbia Shuttle orbiting earth experiences Kapton wire fire.

1985, NASA’s Space Lab used in the shuttle, experiences Kapton wire fire.

March 30, 1987, F-18 Kapton wire fire nearly dooms $32 million aircraft.

November 1982, Air Force’s F-16 experiences Kapton arc-tracking. Pilot/Aircraft lost.

August 24, 1990 US Coast Guard’s E-2C crashed due to Kapton wire fire.

November 2000- US Navy loses 153^rd F-14 out of 600 produced. Requested $360 million in FY 83 to rewire F-14s due to wire to wire shorts caused by premature aging and cracking of Poly-X wire type used in first 323 aircraft produced.

May 31, 1982-December1, 1981- In just six months the Air Force experiences 800 autopilot anomalies due to wiring.

March 1986-US Navy AV-8B in-flight electrical fire caused by Kapton wiring. Fourth occurrence in six month period.

1988 US Military, Canadian and British military ban Kapton.

March 1987, Vermont National Guard F-16, arcing Kapton caused nine wire-bundles to be destroyed.

May 1985, EF 111 Air force jet has a catastrophic explosion of Kapton wires. 92 wires damaged, 29 circuit breakers popped.

September 11, 1986 Marine AV-8B Harrier emergency landing, inoperative critical instruments, several burned bundles of Kapton wires.

January 27, 1982 US Navy F-4, Electrical in-flight fire in circuit breaker 10 inches from co-pilot’s feet. Thick smoke in the cockpit/all electrical power lost. Emergency landing.

October 1987, US Navy A-6 aircraft lost at sea. Kapton wire only suspected cause.

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15 ITEMS NOT POSTED DUE TO LACK OF OTHER SOURCES

11/28/00. DC-9, Air Tran. Flight 956 returned to Hartsfield, Ct after smoke was detected in forward galley and cockpit C/Bs tripped. Evacuation was made on the runway. Passengers were given 1,000 dollars each for lost luggage and claims of luggage damaged in the fire. News wire stories.

http://www.accessaltanta.com/partners/ajc/newsatlanta/airtran_1129.html

http://www.ohio.com/dist/nf/021801.htm

http://dailynews.yahoo.com/h/ap/20001201/bs/plane_fire_1.html

http://www.herald.com/thispage.htm?content/archive/news/yahoo/digdocs/055368.htm

11/16/00. 747, United Airlines. Smoke filled one of the kitchens. Emergency landing at Seattle-Tacoma. News wire story. www.airsafetyonline.com/news/200011/16/5. shtml

11/3/00. 757 American Airlines. 757 reported smoke in the cockpit. Emergency declared and landed in Miami Int’l airport. News http://dailynews.yahoo.com.hwplg/20001103/lo/240762_1.html

10/19/00. 747 United Airlines diverted to Auckland because of electrical problems. News wire story

http://www.pprune.org/ubb/NonCGI/Forum1/HTML/010545.html.

10/18/00. 757, National Airlines. Flight 7002 returned and landed due to a fire in the galley. FAA Incident Reg 546NA. News wire story . http://www.faa.gov/avr/aai/D_1018_N.TXT

10/6/2000. MD-80, American Airlines. Denver to LA Flight 2821 diverted to Bryce Canyon Airport after reports of smoke in the cabin and oxygen masks were deployed. News wire story.

http://more.abcnews.go.com/sections/travel/DailyNews/Emerglanding001006.html.

9/27/2000. MD-80 (or 90), American Airlines. Returned to Omaha Airport after departing DFW and an occurrence of smoke in the cockpit. No further detail.

8/24/99. MD-90. Uni Air. On landing at Hualian, Taiwan flight 873 (Reg B-17912) heard a loud noise from the front of the cabin and thick black smoke poured from one of the overhead compartments on the right side. It took firefighters a half hour to control the blaze. 28 people were injured. News wire story. http://aviation-safety.net/database/1999/990824-0.htm

8/13/00. 757, Continental Airlines. Diverted into Ketchikan with electrical failures. Possible ‘Red Eye’ out of ANC. No details.

7/23/00. 757, British Airways. Possible cabin fire and divert to Heathrow (LHR) . No details.

7/17/2000. MD-80, American Airlines. DFW to Orlando, flight 1258 diverted to Dallas Fort Worth after reports of smoke in the cockpit. Emergency over wing evacuation. AP Wire.

http://more.news.abcnews.go.com/sections/travel/DailyNews/smokecockpit000717.html

6/15/00. MD-80, Continental Airlines. According to FAA records “the 1981 MD80 has been repaired for small cracks, dents, fluid loss, burned wires and electrical problems”. News wire story. http://www.bergen.com/news/lurch200006155.htm

2/29/00. 747-300. Reg # PU-BUH. From EHAM (Amsterdam) to PANC (Anchorage) made a emergency decent into Prestwick (PIC) after report of a main cargo-deck fire. No detail.

7/16/99. American Airlines. Flight 2191 made a emergency landing at the naval station in the Florida Keys after the pilot said he smelled smoke aboard the Miami to Cancun flight with 162 aboard. AP Wire. No details.

3/12/99. 767, United Airlines. Flight 971 Washington to Milan. Smoke detected, emergency and diverted to Newfoundland. CNN News wire. END ____________________________

10 MISCELLANOUS ITEMS NOT POSTED FOR LACK OF ADDITIONAL REFERENCES

1981. TWA asks the Boeing Company not to use Kapton on their 767s. Boeing refuses.

July 12, 1987. Boeing 767-232 has all three autopilots fail.

August 10, 1990. Delta 767-332 made an emergency landing due to loss of engine due to chafed Kapton wiring.

February 1, 1995. Monarch 757, Kapton wire-bundles arc, knocking out cockpit displays.

May 28 1998. Continental 737, arcing wires burn hole in conduit, explosive condition, All 737s grounded with more than 51% showing exposed conductors.

September 22, 1999. SAAB SF-340-B Emergency landing/Smoke in the Cockpit due to chafed wire from autopilot system.

November 1, 1999. Canada’s Transport Canada acknowledges Kapton wire problems. Ref British AAIB Report 52/87.

31 Jan 00. DC-9. Nightingale/Skytrain.Reg # MWT107 While parked at the gate pilot was advised of a fire in the aft Lav with minor damage. Passengers deplaned. FAA Incident *.

March 2, 2000. British Airways 747 Flt 179 experiences abrupt climb injuring 11, FAA determines, “The aircraft experienced an uncommanded autopilot climb”. (USA Today)

March 3, 2000. Kapton banned from use by Austrailian Airline.

109 ADDITIONAL ITEMS POTENTIALLY “WIRE” RELATED BUT NOT SPECIFICALLY MENTIONED

12/7/84, 727, Republic Airlines. TO aborted, smoke and arcing from P611 Panel. Heat and smoke damage near left ground blower. FAA Incident Rpt # 19841207070859C.

4/8/85. DC-9-82. American Airlines. During cruise, C/Bs opened for transformer rectifers at AC Panel. FAA Incident Rpt # 19850408014749C.

12/31/85. DC-3, Private charter. Dense smoke in cockpit from fire originating in aft cabin. Ignition and fuel source undetermined. NTSB Recommendations Rpt # A-85-91.

8/10/86. DC-10, American Trans Air. Fire in the forward cargo hold on the ground. No probable cause determined. NTSB Monthly Rpt. # DCA86IA037.

11/26/86. 727, Continental Airlines. While on ground a cargo fire started. APU generator C/B found smoldering. FAA Incident Rpt. # 19861125069939C.

5/26/87. 737, Southwest Airlines. While in climb, smoke was seen in the aft galley. Pulled breakers, unable to duplicate. FAA Incident Rpt. # 19870526022979C.

11/28/87. 747, South African Airways. Crashed into the sea with all 160 lost. Last ATC communication suggested an in flight fire. NTSB Recommendation Rpt. # A-88-61.

2/3/88. DC-9, American Airlines. Smoke in the cabin, soft/hot floor above cargo area. No causes to the fire were noted. NTSB Recommendation Rpt.# A-88-121 & A-88-128.

4/88. ASRS Pilot report (de-identified). While at cruise, smelled a strong electrical smell, Lost # 1 Main AC and generator. ASRS # 86076.

4/88. 737, Continental Airlines. On final, a fire in the ceiling continued to burn through insulation blankets and duct insulation. Fire department called. Ref. DOT/FAA/CT-91/2.

10/88. ASRS Pilot Report (de-identified). During pre flight a fire erupted in the center pedestal. Even with Halon and power off fire continued to burn. ASRS. # 96957.

1/89. ASRS Pilot Report (de-identified). Aborted TO after a loud noise from Main C/B Panel. 5 C/Bs popped. Tried again, 10 C/Bs popped. Declared Emer. ASRS # 101677.

2/2/89. DC-9, Swissair. Fire developed in the C/B Panel. Flt diverted and Emergency evacuated. Ref. Letter and FAA testimony Senate hearing (103-397) on 11/8/93.

4/89. ASRS Pilot Report (de-identified). Declared a emergency out of IAH and diverted back for Smoke in the cockpit. ASRSRpt # 109853.

4/89. ASRS Pilot Report. After push back at Fayetteville Regional crew advised of smoke in the cabin. Emergency evacuation followed. ASRS Rpt # 109801.

6/89. DC-10, Canadian Airlines. Apparent arcing of light fixture ignited surrounding insulation blankets and the fire spread to ceilings and walls. Ref. DOT/FAA/CT-91/2.

8/17/89. 737, Delta Airlines. While on final, electrical failures, Number 2 and Nunber 3

Power Transformer Rectifier C/Bs had tripped. FAA Incident Rpt.# 19890817052289C.

10/14/89. 727, Delta Airlines. While parked, a muffed explosion and flames came from the vent near seat 3D. No cause was found. NTSB Monthly Rpt. # DCA90MA002.

10/89. ASRS Pilot report (de-identified). Smoke in the cockpit and cabin, declared emergency. Same problem several days later. ASRS Rpt # 127334.

12/1/89. DC-9, American Airlines. At cruise, found electrical smell like an overheated electrical system. Found burnt terminals and C/B. FAA Incident # 19891201062979C.

1/10/90. 747, Northwest Airlines. Found heat damage around aft cargo mid-ship drain mast. Components tested but no probable cause. NTSB Monthly Rpt. # CHI90IA064.

1/90. ASRS Pilot Report (de-identified). Electrical shutdown and cockpit filled with smoke. Declared emergency and diverted. ASRS Rpt. # 134261.

4/6/90. DC-9, Midway Airlines. From cruise, electrical problems. Diverted, replaced C Phase C/B. FAA Incident Rpt. # 19900406022459C.

8/90. ASRS Pilot Report (de-identified). Near VUZ, AL heard loud “Pop” noise followed by the smell of electrical smoke. Informed ATC, continued to IAH. ASRS Rpt # 155020.

09/90. ASRS Pilot Report (de-identified). Immediately after TO from Cleveland Hopkins, smoke in the cabin, emergency declared and returned. ASRS Rpt. # 157942.

9/90. ASRS Pilot Report (de-identified). Left Denver gate, smoke filled cabin. Could not see past 1^st class. PA did not work. Emergency evacuation. ASRS Rpt. # 157908.

2/1/91. DC-9, U.S. Air. On arrival experienced a fire in the aft cargo hold. Bags scorched but no sources within the hold were found. NTSB Monthly Rpt. # MIA91SA230.

11/93. ASRS Pilot Report (de-identified). Near St Louis Int’l at 23,000 attendant reported smoke and fumes in cabin. Declared emergency and landed. ASRS Rpt. # 256013.

11/93. ASRS Pilot Report (de-identified). On taxi out smelled smoke, returned. Next flight, cockpit began to fill with smoke. Emergency divert. ASRS Rpt. # 258014.

4/26/94. 737, Aloha Airlines. Gear position, PA, Interphone and thrust reversers not working. Cabin smoke, evacuation. Source not found. NTSB Monthly Rpt. # LAX94IA206.

6/94. ASRS Pilot Report (de-identified). Rancid cockpit odor on takeoff from Atlanta. Emergency declared. Autopilot inop. Electrical smell noted. ASRS Rpt. # 276367.

7/94. ASRS Pilot Report (de-identified). 737 on takeoff, gear retract, TO warning, transponder, pressurization malfunctioned. Cabin odor. Diverted. ASRS Rpt. # 278033.

7/94. ASRS Pilot Report (de-identified). At cruise following systems failed or faulted; equiptment cooling fan light, Dual DC fail IRS, Battery Buss, anti skid, both N1 and EGT indicators, Com 2, Capt ADI and HIS, autopilot, reverser lights, red gear lights, elevator feel light and PA system. Emergency, saw thick cabin smoke. ASRS # 278111.

9/94. ASRS Pilot Report (de-identified). 727 observed erratic fuel flows and then strong electrical odor in the cockpit. Emergency declared. Fire dept called. ASRS Rpt. # 282510

9/94. ASRS Pilot Report (de-identified). MD-11, both pilots saw smoke coming from overhead cargo test panel. Diverted to EWR.. ASRS Rpt. # 284198.

2/10/95. DC-9, TWA. Smoke in the cockpit, diverted to Omaha. Cause not determined. Aircraft returned to service. FAA Incident Rpt. # 19950210006589C.

2/16/95.DC9, Sunjet Int’l Airlines. At 27,000 experienced a pressurization problem with associated smoke in the cockpit Emergency decent. FAA Incident Rpt 19950216005639C

3/95. ASRS Pilot report (de-identified). Inflight, smoke, fumes and “pop”. Possible window short. Ran checklist. Declared emergency, diverted to BNA. ASRS Rpt 299362.

3/13/95. 737, Delta Airlines. Crackling sound, brief fire, smoke and fumes upper right hand corner of R-1 window. C/Bs did not pop. FAA Incident Rpt. # 19950313006819C.

5/5/95. ASRS Pilot Report. At 27,500 United DC-10 lost all generators. Deployed emergency generator. Emergency landing. No cause found. ASRS Rpt. # 303757.

5/28/96 Martinair 767-31AER experienced repeated electrical anomalies, uncommanded auto-pilot disconnects, changes in airplane zero fuel weight, and blanking of transponder codes. Emergency landing. Kapton wiring suspected. Other anomalies observed on two other 767s. Ref. NTSB Monthly NYC96IA116.

5/15/96. 747. On descent noticed spark under seat 3B. One fire bottle used to extinguish the spark. Ref FAA SDR 1996071100004. (item 18).

9/95. ASRS Pilot Report (de-identified). During cruise heavy smoke in the cabin. Emergency divert to Nassau. Claimed FAA Investigation. None found. ASRS # 315585.

1/96. ASRS Pilot Report (de-identified). 727 at 29,000 smoke came from under FO forward panel. Divert to TLH. Same problem in another 727 weeks later. ASRS # 326301

1/96. ASRS Pilot Report (de-identified). 737 during cruise total loss of all electrical power. After APU start emergency divert to CMH. ASRS Rpt. # 326327.

1/96. ASRS Pilot Report (de-identified). 757 smoke in the cabin. Declared a emergency, landed in San Francisco. ASRS Rpt. # 325089.

2/9/96. DC-9. On take off EPR system C/B popped. Return to gate. Could not duplicate the problem. Ref FAA SDR 1996030800454. (item 14).

2/96. ASRS Pilot Report (de-identified). During clinb smoke billowed out of aft galley. Emergency evacuation on ramp. Cause not determined. ASRS Rpt. # 328795.

2/25/96. DC-9. VALUJET. While sitting at the gate C/B trips for PA, Interphone, No Smoking and Fasten seat Belts. Smoke in cabin. Accomplished VJ E.O. DC-9-3396005. Ref FAA SDR 1996060600422. (item 29).

5/15/96. DC-10. During cruise multiplex system power shorted out and sparked with smoke in the cabin at seats 33DE. Ref FAA SDR 1996052300007. (item 22).

8/96. ASRS Pilot Report (de-identified). 767 East of Nova Scotia smoke in the cockpit. Declared emergency and landed overweight at Sidney. ASRS Rpt. # 344573.

8/14/96. DC-10 While at cruise a oxygen generator activated over Row 26-28. Right side of aircraft had strong electrical smell. Ref FAA SDR 1996082200603. (item 28).

8/30/96. 747. During landing sparks and smoke emited from under seat 31-7. Cable shorted, activated fire extinguisher. Ref FAA SDR 1996102400370. (item 29).

9/4/96. 737, U.S. Air. Gear failed to retract, Air/ground C/B popped. Unable to duplicate the problem. Aircraft returned to service. FAA Incident Rpt. # 19960904033669C.

9/5/96. DC-10, Federal Express. At 33,000ft smoke in the cabin cargo compartment. Emergency landing at Stewart. No cause found. NTSB Monthly Rpt. # DCA96MA079.

9/96. ASRS Pilot Report (de-identified). After TO cabin reported very strong electrical smoke. Emergency return to IAD. C/Bs did not trip, no cause found. ASRS Rpt.# 348982

9/8/00. DC-9. During cruise left engine overheat warning. Declared an emergency and landed. Found tripped C/B, no cause found. Ref FAA SDR 19960911200448. (item 40).

10/20/96. 737, U.S. Air. Smoke in the cockpit, diverted to Ithaca N.Y. FAA Ferry permit was issued. “Case considered closed”. Ref. FAA Incident Rpt. # 19961020037309C.

10/29/96. DC-9. At cruise, B phase C/B popped and then all forward fuel boost pumps, then A phase & others. Unscheduled landing. Ref FAA SDR 1996110100943. (item 46).

11/96. ASRS Pilot Report (de-identified). While at cruise noted strange odor and fumes in cockpit. Equiptment overheat light on. Declared emergency/landed. ASRS 353804.

11/16/96. DC-9. During cruise left AC Buss C/B popped. Numerous C/b trips and system loss followed. Unscheduled landing. Ref FAA SDR 1996121900650. (item 52).

12/96. ASRS Pilot Report (de-identified). While taxiing to gate, smoke came out from behind FO control panel. ASRS Rpt. # 355635.

12/19/96. DC-9. At takeoff, center aft fuel boost pump C/B popped. All quantity gages went blank. Reset failed. Unscheduled landing. Ref FAA SDR 1996122600330. (item 53).

1/97. ASRS Pilot Report (de-identified). 737 during cruise had multiple systems fail. Standby power and APU would not work. Emergency, divert. ASRS Rpt. # 358949.

1/97. ASRS Pilot Report (de-identified). DC-9 on ground had smoke coming from the E&E bay. Fire dept called. Batteries found smoking. ASRS Rpt.# 357142.

3/9/97. DC-10. Overhead cabin panels rows 25 to 26 began arcing and smelled smoke. Unable to find cause. Ref FAA SDR 1997031300703. (item 44).

5/97. ASRS Pilot Report (de-identified). 737 had cabin smoke and heat reported. Emergency declared, diverted to alternate. ASRS Rpt. # 369599.

5/97. ASRS Pilot Report (de-identified). MD-80 at 11,000 feet reported electrical smell in the cabin. Declared an emergency. ASRS Rpt. # 370087.

6/17/97. DC-10, Sun Country Airlines. Smoke in the aircraft. Emergency landing to Denver. Two crew members hospitalized. NTSB Monthly Rpt. # FTW97IA227.

10/97. ASRS Pilot Report (de-identified). While taxiing cabin reported increasing electrical smoke. C/Bs did not pop. Return to gate. Next flight same again. ASRS 382946

10/29/97. DC-9. During cruise lavatory door, when locked, shocked a passenger. Replaced wire. Ref FAA SDR 1998042800555. (item 98).

11/97. ASRS Pilot Report (de-identified). 767-200ER had electrical smoke. Declared emergency, returned to the Azores. Second such diversion/month. ASRS Rpt. # 385050.

12/19/97. 737, Sinapore Airlines. Reg # 9V-TRF. Flight MI-185 exploded in mid-air. Ref. http://www.airdiasters.co.uk/191297.htm . No cause or Report available here.

12/19/97. MD-80, Alaska Airlines. Taxiing to gate when cabin filled with smoke. Over wing evacuation to the taxiway. Ref. www.ntsb.gov/Publictn/2000/SS0001.pdf “case 4”.

12/25/97. 737, United Airlines. In flight smelled electrical burning and noted landing gear C/B popped. Left main gear collapsed on landing. Ref. www.ntsb.gov/Publictn/2000/SS0001.pdf ,“case 5”.

1/7/98. MD-11F. Inspection found wiring burned up beneath center cargo floor. Also noted bellframe burned through. Ref FAA SDR 1998011500120. (item 40).

1/11/98. Boeing 767 Emergency landing, Kapton wires arced popping circuit- breakers and smoke in the cabin. Ref Boeing Service Message M-7200-98-00140, 6/21/98.

1/19/98. 737, Continental Airlines. Enroute, C/Bs for # 1 Main, aft boost in # 2 Main and both pumps in the center and aux fuel tank popped. Only 2 pumps remained operational Replaced C/B #65. Ref. FAA Incident Rpt. # 19980119002309C. Case closed.

1/9/98. Boeing 767 emergency landing due to intermittent leading edge disagreement, electrical smoke and fumes in the cabin. Ref Boeing Service Message M-7200-98-00140, 6/21/98. (Ref NTSB Monthly DCA98RA016).

3/2798. DC-9. Air Canada. On taxiout, experienced a electrical fire in the cockpit overhead panel. Source was ignition switch. NTSB Monthly Rpt. # CHI98A110.

3/30/98. 727 Royal Airlines. Ft Lauderdale. Before TO crew smelled smoke in the cockpit. Flames and smoke coming from the overhead panel. Evacuated using chutes.Ref. NTSB www.ntsb.gov/Publictn/2000/SS0001.pdf ,“case 13”.

4/4/98. 767, Brittania. Diverted by damaged sidewall heater and arcing electrical fire burned a hole in a panel and insulation blankets. AAIB of Iceland to investigate. NTSB Monthly Rpt. DCA98WA046.

4/98. ASRS Pilot Report (de-identified). At cruise, smelled strong electrical smell. Haze in the cabin. Made straight in landing. ASRS Rpt. # 40075.

4/98. ASRS Pilot Report (de-identified). C/B popped for left AC Buss. Reset but popped again. Could not reset again. Emergency and diverted to Detroit. ASRS Rpt.# 400849.

4/98. ASRS Pilot Report (de-identified). Enroute, Transfer Buss C/B popped. Would not reset. Lost instruments and pressurization control. Emergency / divert. ASRS # 400987.

5/15/98. Type ?, United Airlines. Smoke, sparks and flames from C/B Panel C787. Fire put out, flight landed and 411 passengers offloaded. FAA Incident # 19980515014099C.

5/98. ASRS Pilot Repot (de-identified). Lost all cabin PA systems. Smelled electrical odor in cockpit. Called for emergency equipment and landed. ASRS Rpt. # 401039.

6/22/98. 757-2Y0, Air 2000 Ltd. Experienced a loud bang and sparks from cockpit overhead panel. Flight diverted. UK AAIB investigating. NTSB Monthly DCA98WA057.

7/98. ASRS Pilot Report (de-identified). 737 noted cracking sound behind C/B panel. Equipment and pressurization failures. Diverted to alternate. ASRS Rpt. # 408309.

8/98. ASRS Pilot Report (de-identified). 767-300 abeam of Nova Scotia had smoke in the cockpit. Declared emergency, landed overweight at Sydney, N.S. ASRS Rpt. # 344573.

3/22/99. DC-10. During cruise a loud spark arced, then several more times later in flight near the lower inst panel. No cause found. Ref FAA SDR 1999041700441. (item 104).

4/7/99. 737, Turkish Airlines. Became engulfed in fire shortly after TO and crashed. Ref. http://www.airdiasters.co.uk/070499.htm . No cause or Report found here.

6/22/99. 737, United Airlines. Enroute, smoke in the cabin. Diverted to Scottsbluff. Unable to find cause, returned to service. FAA Incident 19990622018839C. Case Closed.

7/31/99. 737. For Two Flights, during climb had engine overheat fault. Unscheduled landings. Replaced engine soft core harness. Ref FAA SDR 1999090300679. (item 366).

9/8/99. 747. During cruise lost 50 % electrical power. Unscheduled landing. Wire/water contaminated in galley. Ref FAA SDR 2000022300014. (item 157).

2/26/00. DC-9/80, U.S. Air. Reg # USA1248. At Indianapolis, Pilot declared smoke in the cockpit. Two Flight attendants hospitalized for smoke inhalation. FAA Incident*.

5/7/00. 717 Air Tran Airways. Smoke in the cockpit coming from near the fuel pump switches. Declared an emergency. No cause, switches sent for tests. NTSB MIA00SA147.

7/12/00. 727, Federal Express. Reg # FDX3106. Smoke in the cockpit. Declared an emergency and evacuated on the runway at Fort Worth. FAA Incident. Source; www.faa.gov/avr/aai/D_0717_N.TXT

7/12/00. 777-200, British Airways. Enroute Toronto to London reported smoke in the cockpit and declared a emergency, divert to Montreal. Cadors Rpt 2000A0378.

7/21/00. DC-9, Northwest Airlines. Reg # 671Mc. On TO had smoke in the cockpit. Returned and evac pax to the runway. FAA Incident faa.gov/avr/aai/D_0724_N.TXT

8/10/00. 767, Delta Airlines. DAL 139 enroute Manchester to N.Y. reported electrical smoke in the cockpit East of Labrador. Diverted to Goose Bay. Cadors Rpt # 2000A0454.

10/18/00. 757, National Airlines. Flight 7002 returned and landed due to a fire in the galley. FAA Incident Reg 546NA. http://www.faa.gov/avr/aai/D_1018_N.TXT

11/11/00. 737, U.S. Air. Reg # USA1862. Reported smoke in the cabin. Unknown. FAA Incident. http://www.faa.gov/avr/aai/D_1113_N.TXT

11/15/00. 747, United Airlines. Reg # UAL809. Flight 809 reported smoke in the galley. Emergency and diverted to Seattle. FAA Incident www.faa.gov/avr/aai/D_1116_N.TXT

11/20/00. A-300, American Airlines. At 16,000 feet neither pressurization controllers would work. F/A chimes sounded eratically and the forward lav smoke detector sounded. After landing, ram air switch would not depressurize aircraft. Captain then reported a fire and called to emergency evacuate. F/A opened a door and was expelled from the aircraft and killed. NTSB Monthly MIA01FA029.

11/29/00. MD-80, American Airlines. Flight 1683. Flight attendant report of smoke in the cabin. Emergency landing at Reagan Nat’l and evacuation to the ground using slides and chutes. FAA Incident http://www.faa.gov/avr/aai/D_1130_N.TXT

Limitations

The aircraft events listed here are limited to the larger types of commercial transports, all reports to the commuter-type craft (i.e. Beech, Saab, ATRs) were discarded even though they also operated under the same Part 121 commercial carrier rules and, as the same carriers seen in this report, shared the same materials in wiring insulation types and insulation blanket (batts) used in their ‘big cousins’.

Under reporting is a big problem and as NASDAC had noticed, there are significant limitations to the self-reporting processes and such may apply in the Aviation Safety Reporting System Database (ASRS) Reports used here. The same limitations may well apply to the newly announced system by the White House in late January 2000 dubbed the Aviation Safety Action Program (ASAP). This encompasses virtually all of the claims cited for the creation of the earlier ASRS system in 1983, including immunity from prosecution and claims for heightened safety awareness and information sharing.

The NASDAC studies (see source on page 12) also noted that such aviation mishaps subject to self reporting often go unreported because of; (1) by themselves, they may appear insignificant, (2) the event wasn’t intentional, (3) no one is hurt because of back up systems or (4) no collation is seen to other events. The latter may easily be attributed to lack of information sharing, which ironically, is why these programs were set up in the first place. Never-the-less, NASDAC agrees the actual calls placed to ASRS are but a fraction of the industry incidents and occurrences.

Moreover, NASDAC made note of the Heinrich Pyramid (see source on page 15) whereas for every given major accident, there will be 3-5 less significant accidents, and among 7-10 incidents, there may be at least several hundred unreported occurrences. Thus, with the ASRS voluntary reports here, unreported incidents may have ranged considerably higher.

The FAA’s Service Difficulty Reporting Lastly, a separate IASA Study demonstrated that within the Office Of System Safety Databases, and all linked to a common search engine, that the FAA Incident Data System Reports reflected but less than 5 % of the combined reports from the other databases listed there.

Edited by jking1@mediaone.net. Questions or requests for further documents may be directed here.

John D. King

IASA Data Specialist

The International Aviation Safety Association is a non profit safety organization incorporated in Delaware.

See our website at www.iasa.com.au .

Last revised 1/10/01.