Amateur Build Safety
Transcription
Amateur Build Safety
Why Is My Airplane Trying To Kill Me? A Presentation on Homebuilt Aircraft Safety By Will Fox, CFI, TC, FA Email: [email protected] 2/16/14 Page 1 Risk Triple Distillation Theory ! Pilots, in general, are willing to accept a higher level of risk than much of the population – 1 in 500 people in the US are pilots. ! Homebuilt pilots are willing to accept a higher risk than pilots of certified aircraft. – Homebuilt aircraft have a fatality rate that is 3 times greater than comparable certified aircraft. ! Pilots who test fly homebuilt aircraft are willing to accept a still higher risk during initial testing. – The accident rate in Phase I testing is 5 times greater than in Phase II operation . ! ! One might infer that this process results in a triple distillation of risk tolerance. Homebuilder/pilots should be aware of this and consider ways to mitigate the risks they accept. 2/16/14 Page 2 Why Is My Airplane Trying To Kill Me? ! ! ! ! Homebuilt safety Myths What are the accidents telling us? What can we do to improve the safety of homebuilt aircraft? Homebuilt Aircraft Safety Score 2/16/14 Page 3 Homebuilt Safety Myths-Part I ! ! Myth #1: Homebuilt aircraft are just as safe as GA aircraft. Truth: Fatal accidents occur about 3 times more often than in similar GA aircraft on a per hour of operation basis. Homebuilt aircraft can also have less forgiving flight characteristics particularly with regard to stall/spin behavior. Myth #2: Auto engines can be just as reliable as aircraft engines and a lot cheaper. Truth: Auto engines converted for aircraft use fail at a significantly higher rate than traditional aircraft engines and often require more maintenance. When all the costs are considered, the cost of traditional aircraft engines and auto conversion engines are more competitive than most people think. 2/16/14 Page 4 Homebuilt Safety Myths-Part II ! ! Myth: Homebuilts are built out of modern material like fiberglass and carbon composite and therefore are stronger in a crash. Truth: Composite materials can be quite strong, but they have many times less ductility than the equivalent steel or aluminum structure and therefore are less able to absorb energy and mitigate impact loads in a crash unless specifically designed to do so. Composites break, metals bend. Myth: You will have to give up performance to improve the safety of homebuilts. Truth: Crashworthiness is an aspect of performance as well, and one that can save your life. Improving safety doesn’t mean that you have to give up performance in other areas. The Bonanza, which is noted for its performance characteristics, has a cabin designed for impact loads up to 25 gs. The Cirrus, another high performance aircraft, has a seat designed to crush in a graded manner to allow the occupants to survive much higher vertical speed impacts. 2/16/14 Page 5 Increase in Homebuilt Accident Rate Acknowledged By EAA in April 2009 ! ! ! ! ! April 2009 EAA issued a Safety Wire News article to Flight Advisors and Technical Counselors about increasing accident rates for homebuilt (Experimental Amateur Built - EAB) aircraft. The EAA and the FAA were becoming concerned with the deteriorating safety record for EAB aircraft, The accident rate for Amateur built aircraft increased by 40% from 20042007. The accident rate for AB aircraft in 2008 was 3.5 times greater than personal use General Aviation aircraft. High performance AB aircraft such as the Lancair and Vans RV are having a disproportionate amount of accidents. 2/16/14 Page 6 NTSB Issues EAB Safety Study In May 2012 ! ! ! The NTSB is concerned about EAB aircraft safety and conducts a study to compare EAB aircraft and non-EAB aircraft safety in May 2012. The study indicates that EAB aircraft have three times the fatality rate of nonEAB aircraft. The study is composed of four major elements. – Comparison of EAB to Non-EAB accidents for the past 10 years. – In-depth investigation of all EAB accidents in 2011. – Analysis of EAA Survey data. – Discussions between NTSB,FAA, EAA, kit manufacturers, and EAB builders and owners. ! They come up with 12 recommendations for the FAA and 4 recommendations for the EAA. 2/16/14 Page 7 EAB Aircraft Crash Twice as Often As Non-EAB Aircraft ! Based on a study by the NTSB that compared Experimental Amateur Built (EAB) aircraft which were represented by single engine, piston powered, amateur built aircraft (fixed wing, helicopter, balloons, gliders, and gyroplanes) to Non-EAB aircraft that were similar type aircraft but composed of standard category and light sport aircraft, the following observations can be made: – EAB aircraft crash about twice as often as Non-EAB aircraft both on a fleet basis and on an hours flown basis. – EAB aircraft crashes are much deadlier than non-EAB aircraft, because fatalities occur 50% more often when a crash does occur. 2/16/14 Page 8 Loss Of Control In Flight and Powerplant Failures Cause Most EAB Accidents ! ! ! Almost 60% of fatal EAB aircraft accidents are due to two things, Loss of Control in Flight and Powerplant Failures. By comparison, these same two categories represent 45% of Non-EAB aircraft fatal accidents. Non-EAB aircraft, however, have a much higher accident rate than EAB aircraft when it comes to weather related accidents. 2/16/14 Page 9 The Pilot is the Most Important Safety Device in the Plane, But They Need Help ! ! ! ! ! About 75% of the aircraft accidents that occur are attributed to Pilot Error in one way or another. The aviation community has been trying to solve this problem in the General Aviation sector for many years with limited success. Pilots don’t go out and crash planes on purpose. They are human and therefore subject to error. The question is not how do we completely eliminate human error, but rather, how can we mitigate the consequences when it occurs. 2/16/14 Page 10 Two Of The Most Important Things You Can Do to Avoid An Accident ! ! Improve your stall warning equipment and your stall/spin awareness. Make your propulsion system as reliable as you can. 2/16/14 Page 11 Loss of Control In Flight Accidents Are Dominated By Stalls And Spins ! ! ! ! ! Rich Stowell1 states that 45% of the homebuilt fatal accidents are preceded by a stall or a spin. Many homebuilt aircraft have no stall warning device and no appreciable aerodynamic buffeting prior to a stall. Some homebuilt aircraft exhibit abrupt stall behavior and stall asymmetrically, resulting in a spin entry. Stalls such as these may require hundreds or even thousands of feet to recover from. Because the stall or spin is a surprise, initial pilot responses often aggravate the stall or spin. 1. Rich Stowell’s Book - The Light Airplane Pilot’s Guide to Stall/spin Awareness 2/16/14 Page 12 How Can We Prevent Stall/Spin Accidents? ! ! ! ! Install a Stall Warning or Angle of Attack (AOA) device in your Homebuilt. Implement stick shakers and automatic stall prevention or recovery systems. Improve the stall characteristics of existing aircraft with: – Vortex generators – Stall fences – Stall trip devices Design more “Spin Resistant” aircraft using NASA technology – Discontinuous leading edge cuffs – Stall control wing slots – Slats 2/16/14 Page 13 Effectiveness of Stall Warning Devices ! According to several FAA studies: – Stick Shakers are by far the most effective stall warning device. " Pilots responded 99% of the time with an average response time of 1.1 seconds. – Interrupted stall horn was second best stall warning device. " Pilots responded 85% of the time with an average response time of 1.5 seconds. – Continuous stall horn was the third best stall warning device. " Pilots responded 64% of the time with an average response time of 1.7 seconds. – Pilots prefer and respond better to stick shakers and even aerodynamic buffeting than aural stall warnings. – AOA indicator used in conjunction with a stall horn or Stick Shaker were found to be the most effective. – Stall lights are the least effective. 2/16/14 Page 14 Powerplant failures Cause About 1 out of 4 Homebuilt Aircraft Accidents ! ! ! ! The NTSB found that 23% of the EAB accidents were caused by powerplant failures versus 14% for Non-EAB aircraft. Ron Wanttaja2 found that about 13% of the accidents involving fixed-wing homebuilts with traditional powerplants were due to engine failures, versus over 35% for aircraft with auto engines. The most likely failures in Auto Engine Conversions were ignitions and cooling systems and the reduction drive system. In the accidents that resulted from builder errors, 1/3 were due to fuel system problems and another 30% were due to builder mistakes with the engine or drive line. 2. Ron Wanttaja - Homebuilt Aircraft Safety 1998-2006 2/16/14 Page 15 How Can We Prevent Aircraft Powerplant Failures? ! ! ! ! Conduct Fuel Flow testing. Encourage the use of proven aircraft engines in homebuilts. Increase the use of EAA Technical Counselors and A&Ps with regard to inspection of fuel systems and firewall forward installations. Educate homebuilders about important measures of engine performance and longevity, and encourage nontraditional aircraft engine builders to publish relevant reliability data and maintenance requirements for aircraft engines so homebuilders can make intelligent choices. – – – – ! Mean Time Between Failure (MTBF) Time Between Overhaul (TBO) Brake Mean Effective Pressure (BMEP) Mean Piston Speed (MPS) Offer lower insurance rates to homebuilders who use more reliable and proven engines. 2/16/14 Page 16 Homebuilt Aircraft Are Not Especially Crashworthy ! ! It is difficult to find data on the crashworthiness of homebuilt aircraft, but we can make a few observations. Many homebuilts do not exhibit crashworthy features such as: – Cabins designed to protect occupants – – – – – – ! that include roll cages. Cabins that remain intact following an impact. Seats designed to limit impact loads. High integrity restraint systems. Engine locations that are not hazardous. Fuel storage outside of the cabin. Firewall and engine cowl designs that resist nose-overs. One might observe that crashworthiness is not a key consideration in most homebuilders’ minds, since it is not typically part of a homebuilder’s purchase decision, nor a feature advertised by kit manufacturers. 2/16/14 Page 17 What Can We Learn From Very Crashworthy Aircraft - Crop Dusters? ! ! Experts agree that 85% to 90% of all aircraft crashes can be survivable with incorporation of crashworthiness features. Let’s look at features in an aircraft where crashworthiness is one of the most important performance characteristics - A Crop Duster. – Internal steel roll cages – Large amount of structure (engine and hopper) in front of pilot to absorb impact forces. 5 point restraint system Energy-absorbing landing gear Self-sealing fuel tanks and lines 14g collapsible seats Wire cutters Helmets ! – – – – – – All of the pilots in the pictures shown to the right of crop duster crashes survived, and most had little or no injury. 2/16/14 Page 18 There Is A Substantial Knowledge Base For The Design Of Crashworthy Aircraft ! The AGATE Small Airplane Crashworthiness Design Guide has much to offer in terms of how to design more crashworthy aircraft. – – – – – ! ! Crash Physics Biometrics Airframe and Seat Crash Resistance Restraints Systems Delethalizing Interiors and more AGATE establishes test conditions for survivable impacts. AGATE provided design goals for the cabin structure that would make aircraft accidents much more survivable. 2/16/14 Page 19 Stall Speed Is Important To Making Homebuilt Crashes More Survivable. ! ! ! ! Stall Speed strongly effects the amount of energy that has to be absorbed in a crash. There is 4 times the energy to dissipate at 60 kts as there is at 30 kts. Light aircraft with stall speeds less than 45 knots have high crash survivability. Light aircraft with stall speeds greater than 75 knots have almost zero crash survivability. The FAA mandated a maximum stall speed of 61 knots for certified aircraft less than 6000 lbs to improve crash survivability. Crash survivability plot by by Barnaby Wainfan from “Wing Design: Major Decisions” presentation 2/16/14 Page 20 A Fire Following A Crash Is A Very Deadly Event ! Your chances of surviving a fire following an aircraft crash are very low. – In 1998, a safety analysis of 68 GA aircraft accidents revealed that 22 pct of the crashes involved post-crash fire. Forty-eight pct of the occupants in these accidents were fatally injured3. – The crash scenarios evaluated in the study were selected to approximate the limits of survivability, and the statistics obtained from their analysis suggest that although there are not a large number of GA aircraft crashes involving post-crash fire, the accidents that do involve fire are extremely lifethreatening for the occupants. ! ! ! ! Modern light aircraft designers avoid storing fuel in the cabin area. They also seek to protect fuel lines and fuel selector valves in the event of a crash. Crop dusters use self-sealing fuel tanks and lines. Recently, Robinson Helicopter Co. began installing self-sealing tanks in their helicopter, because the occupants were being killed by fire far more often than by the crash impact. Avoid installing fuel tanks in front of the cabin and in front of the spars of the wings where they are likely to be damaged in crash. 3. Chapter 10 of the AGATE Small Airplane Crashworthiness Design Guide. 2/16/14 Page 21 Four Things You Can Do To Improve Your Homebuilt’s Crashworthiness ! ! ! ! ! Provide 4 or, better yet, 5 point restraints systems for all occupants. Use inertial reels on shoulder harnesses. Eliminate sharp edges in the cabin and use energy absorbing materials on potential impact zones. Use fireproof or fire resistant materials for the interior. Big Tires:-) 2/16/14 Page 22 Some Crashworthy Features To Look For In A Homebuilt ! ! ! ! ! ! ! ! ! ! Excellent stall behavior and spin resistant features. Engines designed for aviation applications. Cabins with roll cages and with safe flail zones that are designed to protect occupants up to the AGATE guidelines. Seats that are designed to remain attached to the cabin structure and to attenuate impact decelerations based on the AGATE guidelines. Firewalls and Fuselage design features that are designed to resist “digging-in” and noseovers. Fuel that is stored outside and away from the cabin and fuel tanks that are crash resistant or even incorporate self sealing bladders. Controls that are located to the side of the occupants. Multiple egresses for emergencies. Seat belt pretensioners. Airbags. 2/16/14 Page 23 We Can Make Your Homebuilt Safer - A Lot Safer ! ! ! ! ! ! ! Given the innovativeness shown by the homebuilt community, there is great opportunity for improving Homebuilt Safety. The knowledge and technology exist already. We just need to apply them. Communicating the facts is extremely important, so builders know what is safe and what isn’t, so they know where to apply their energies to make their aircraft safer. Safe aircraft do not have to have lower performance. Look at the stall characteristics of the Questair Venture, or the cabin integrity of a Bonanza, or the seat design of a Cirrus. Safe aircraft do not have to be expensive aircraft. The cost of quadrupling the crash survivability of cars over the last 30 years, was only about 1/15 of the price of the car (about $1500 for $22,000 car)4. There is no reason to believe that we can’t accomplish as much in homebuilt aircraft. Try to imagine how much better you and your passengers would feel flying an aircraft that is four times safer than most other GA aircraft - it would be great! It is not only doable, but it is also the right thing to do. 4. Daniel Sperling, “The Price of Regulation, Fall 2004 2/16/14 Page 24 Homebuilt Aircraft Safety (HAS) Score ! ! ! ! ! ! ! Wouldn’t it be great if we had a way to score a homebuilt aircraft on safety? We should be able to, by considering the safety features that we have been discussing. We know that stall speed, spin resistance, and engine reliability are important, as well as the crashworthiness of the cabin, seats, restraints, and other features. We should be able to evaluate to what degree a homebuilt incorporates these features, and by weighting them appropriately, come up with a scorecard. The next ten slides show you some examples of how to do that and to come up with a Homebuilt Aircraft Safety Score (HASS). If we do it right, there should be some correlation between the HAS score and the likelihood of an accident being fatal for a particular type of aircraft. I picked eight aircraft for assessment: " RV-7/7A " Lancair IV " Sonex " Zenair 701 " Varieze " Cessna 172 " Questair Venture " Pegazair Zenair 701 Survivable Accident Percentage - 89% HAS Score=125 Varieze Survivable Accident Percentage - 73% HAS Score=85 RV-7/7A Survivable Accident Percentage - 65% HAS Score=80 Lancair IV Survivable Accident Percentage - 49% HAS Score=40 2/16/14 Page 25 Homebuilt Aircraft Safety Score 1- Stall Speed Stall speed (60 points) A. Stall speed 31 knots or less – 60 points. B. Stall speed 41 knots or less – 35 points. C. Stall speed 51 knots or less – 20 points. D. Stall speed 61 knots or less – 15 points. E. Stall speed 71 knots or less –10 points F. Stall speed over 71 knots - 0 points. " " " " " " " " RV-7/7A -20 points Lancair IV - 0 points Sonex - 35 points Zenair 701 - 60 points Varieze - 15 points Cessna 172 - 20 points Questair Venture - 15 points Pegazair - 60 points 2/16/14 Page 26 Homebuilt Aircraft Safety Score 2 - Stall/Spin " " " " " " " " Aircraft Stall/Spin Characteristics (40 points). A. Spin proof. The aircraft will not enter a spin - 40 points. B. Spin resistant. The aircraft resists entering a spin The aircraft resists entering a spin as prescribed by FAR Part 23 - 30 points. C. Acceptable stall/spin behavior. The aircraft has docile stall characteristics and clear aerodynamic warning; a stall warning device; effective ailerons in a stall; sufficient rudder to level wings in a stall and to recover from an incipient spin with a minimum altitude loss (<1000 ft) – 10 points. D. Poor Stall/spin behavior. The aircraft has abrupt stall characteristics with little or no warning; ailerons are ineffective during a stall; aircraft is not recoverable from a spin or requires excessive altitude to recover from an incipient spin (>1000 feet) – 0 points. RV-7/7A - 10 points Lancair IV - 0 points Sonex - 10 points Zenair 701 - 30 points Varieze - 30 points Cessna 172 - 10 points Questair Venture - 10 points Pegazair - 30 points 2/16/14 Page 27 Homebuilt Aircraft Safety Score 3 - Cabin Structure Cabin Structure (20 points). A. Meets or exceeds AGATE Preferred Cabin structural load factors and survivable volume requirement. The aircraft has multiple exits and resists nose over - 20 points. B. Meets the AGATE Minimum Cabin structural load factors and survivable volume requirement. The aircraft resists nose over – 15 points. C. Meets the FAR Part 23 Emergency Landing Conditions but does not meet a specified survivable volume requirement or occupant deceleration limit – 10 points. D. Cabin structure does not meet any recognized standard for crashworthiness - 0 points. " " " " " " " " RV-7/7A - 10 points Lancair IV - 0 points Sonex - 10 points Zenair 701 - 0 points Varieze - 0 points Cessna 172 - 15 points Questair Venture - 10 points Pegazair - 0 points 2/16/14 Page 28 Homebuilt Aircraft Safety Score 4 - Restraint System " " " " " " " " Restraint System for all occupants (20 points). A. 4 or 5 point restraint system. Satisfies the AGATE Preferred 26g forward deceleration requirement. Incorporates inertia reels and airbags - 20 points. B. 4 point restraint system. Satisfies the AGATE Minimum 9g forward deceleration requirement. Incorporates inertia reels - 10 points. C. 3 point restraint system – 5 points. D. 2 point restraint system – 0 points. RV-7/7A -10 points Lancair IV - 5 points Sonex - 10 points Zenair 701 - 5 points Varieze - 10 points Cessna 172 - 5 points Questair Venture - 5 points Pegazair - 10 points 2/16/14 Page 29 Homebuilt Aircraft Safety Score 5 - Powerplant " " " " " " " " Powerplant (15 points). A. Aircraft uses a traditional aircraft engine such as a Lycoming, Continental, or Clone. Aircraft uses a propeller by a major manufacturer such as Hartzell or McCauley. Aviation rated components are used firewall forward – 15 points. B. Aircraft uses a Rotax four stroke engine. Aircraft uses a propeller tested and manufactured to a recognized certification standard – 10 points. C. Aircraft uses an engine and propeller designed for aircraft applications that has been tested and manufactured to a recognized certification standard – 5 points. D. Auto conversion or 2-stroke engine or propeller that has not met any recognized certification standard – 0 points. RV-7/7A -15 points Lancair IV - 15 points Sonex - 5 points Zenair 701 - 5 points Varieze - 15 points Cessna 172 - 15 points Questair Venture - 15 points Pegazair - 15 points 2/16/14 Page 30 Homebuilt Aircraft Safety Score 6 - Seats " " " " " " " " Seats (15 points). A. Seats meet AGATE Preferred Structural Load Factors or new FAR Part 23 (26 g forward, 16.5 g downward and 4.5 g sideways). Seats incorporate energy absorption device to limit impact loads. Seats or restraint system designed to prevent submarining - 15 points. B. Seats meet AGATE Minimum Structural Load Factors or old FAR Part 23 requirements (9 g forward, 6 g downward and 1.5 g sideways). Seats or restraint system designed to prevent submarining - 5 points C. Seats do not meet AGATE or FAR Part 23 design or test requirements 0 points RV-7/7A - 0 points Lancair IV - 0 points Sonex - 0 points Zenair 701 - 0 points Varieze - 0 points Cessna 172 - 5 points Questair Venture - 0 points Pegazair - 0 points 2/16/14 Page 31 Homebuilt Aircraft Safety Score 7 - Cockpit Protrusions " " " " " " " " Cockpit protrusions (10 points). A. Cockpit is padded to protect occupants from impact injuries. Collapsible control columns or offset controls are used. Cockpit has no protrusions or all protrusions are padded – 10 points. B. Cockpit has protrusions, and controls represent impact hazards– 0 points. RV-7/7A - 0 points Lancair IV - 10 points Sonex - 0 points Zenair 701 - 10 points Varieze - 10 points Cessna 172 - 10 points Questair Venture - 10 points Pegazair - 10 points 2/16/14 Page 32 Homebuilt Aircraft Safety Score 8 - Fuel System " " " " " " " " Fuel System (5 points). A. Fuel flow system uses one fuel selector valve and meets fuel flow requirements of AC90-89A – 5 points B. Fuel flow system uses multiple fuel selector valves or does not meet fuel flow requirements of AC90-89A – 0 points. RV-7/7A - 5 points Lancair IV - 5 points Sonex - 5 points Zenair 701 - 5 points Varieze - 5 points Cessna 172 - 5 points Questair Venture - 5 points Pegazair - 5 points 2/16/14 Page 33 Homebuilt Aircraft Safety Score 9 - Fire Resistance " 1) Fire resistance (5 points) A. No fuel storage in the cockpit. Fire resistant materials used for the interior. Fuel lines are fire sleeved or metal– 5 points. B. Fuel stored in the cockpit. Fuel lines are not fire resistant. Interior is constructed of materials that aren’t fire resistant – 0 points. RV-7/7A - 5 points Lancair IV - 0 points Sonex - 0 points Zenair 701 - 5 points Varieze - 0 points " Cessna 172 - 5 points " " " " " " Questair Venture - 5 points Pegazair - 5 points 2/16/14 Page 34 Homebuilt Aircraft Safety Score 10 - Engine Location " " " " " " " " Engine location (5 points) A. Engine in front of the pilot – 5 points. B. Engine behind the pilot with no appreciable crash mitigation features– 0 points. RV-7/7A - 5 points Lancair IV - 5 points Sonex - 5 points Zenair 701 - 5 points Varieze - 0 points Cessna 172 - 5 points Questair Venture - 5 points Pegazair - 5 points 2/16/14 Page 35 Homebuilt Aircraft Safety Score Observations ! Total Score (out of 195 points possible): " " " " " " " " ! ! ! RV-7/7A -80 points Lancair IV - 40 points Sonex - 80 points Zenair 701 - 125 points Varieze - 85 points Cessna 172 - 95 points Questair Venture - 80 points Pegazair - 140 points The higher the score, the safer the aircraft is and the less likely that an accident will be fatal. Metal aircraft with low stall speeds and good stall/spin characteristics, such as the Pegazair and Zenair 701, get high HAS scores. Aircraft with high stall speeds and poor stall/spin characteristics, such as the Lancair IV get low HAS scores. 2/16/14 Page 36 Crash Survivability Percentage ! ! Taking the last twenty years of data from NTSB accident reports and determining the ratio of nonfatal accidents to total accidents for a particular aircraft produces a Crash Survivability Percentage. The Crash Survivability Percentages for the aircraft used as examples in the HAS score are: " " " " " " " " ! ! ! RV-7/7A -65% Lancair IV - 49% Sonex - 83% Zenair 701 - 89% Varieze - 73% s Cessna 172 - 86% Questair Venture - 61% Pegazair - 100% The Crash Survivability Percentage shows a good correlation with the HAS score, indicating some validity in the approach to scoring. Once again, aircraft like the Pegazair and the Zenair 701 have a high survivability and aircraft like the Lancair IV do not. There are exceptions though, as can be seen by the HAS score for the Sonex when compared to the Crash Survivability Percentage. One variable not considered in this analysis is the type of pilot a particular homebuilt attracts, and the type of flying they do. 2/16/14 Page 37