Showing posts with label failure. Show all posts
Showing posts with label failure. Show all posts

Airbus ends A340 era, selling last two aircraft, defaulted by Kingfisher Airlines

European airframer Airbus S.A.S. announced the sale of the last two A340-500 aircraft in its inventory, marking an end of the longest range model of its portfolio.
AJW Capital Partners Limited, a worldwide aviation services group based in the UK, has signed a firm contract for the purchase of two Airbus A340-500s aircraft. With this order AJW Capital becomes the newest Airbus aircraft customer. Powered by Rolls-Royce Trent 500 engines the aircraft features a comfortable two-class cabin for maximum passenger appeal. Commercial service will begin with an existing AJW Group customer early 2013.
The two aircraft MSN (Manufacturer Serial Number) 886 and MSN 894 were the last two of the five A340-500's ordered by Indian carrier Kingfisher Airlines, who defaulted on taking delivery of the entire order. The A340s with their ultra-luxurious cabin product were meant to be the flagships of the fleet with these two airframes originally allocated registration numbers VT-VJA and VT-VJB. Three aircraft from the order were sold by Airbus to Nigerian carrier Arik Air.

The four engined A340 series in general, and the A340-500 in particular was the least profitable aircraft for Airbus. With the rising costs of fuel, the ultra-long-haul (ULH) flights, the 282 seat A340-500, was designed for, no longer were viable. Airbus has been buying back A340s from airlines to help sales of the more efficient twin-engined sister, the A330, one of the most profitable aircraft for Airbus.

The two A340-500s appear to be destined to AZAL Azerbaijan Airlines with two Embraer 170s of another failed Indian airline, Paramount Airways. Swiss industry news website, ch-aviation, reports
AZAL has also acquired two ex-Paramount Airways (India) EMB-170s (c/n 17000002 and c/n 17000005) from Embraer subsidiary ECC Leasing that will already join the fleet in spring of next year. In other news, AZAL plans to add two A340-500s (c/n 886 and c/n 894) to its fleet for long-haul services that were originally ordered by Kingfisher Airlines, and then never delivered.
We opine that Azal will put these aircraft on a Baku-New York route.
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NTSB issues urgent safety alerts for GEnx engines; Air India, JAL, Ethiopian, Qatar 787 Dreamliners affected

The National Transportation Safety Board, the independent safety investigator of the United States, has issued two urgent safety recommendations (A-12-52 and A-12-53) on General Electric GEnx engines, which power the latest generation of Boeing aircraft; the 787 Dreamliners and the Boeing 747-8 both freighters and Intercontinental passenger jets.

The GEnx-1B engines power the 787 Dreamliners operating with Air India, Japan Airlines (JAL), Ethiopian Airlines, and soon, Qatar Airways. The two other 787 operators All Nippon Airways (ANA) and LAN Chile, have their aircraft powered by the Rolls Royce Trent 1000 engines.

The GEnx-2B engines power the Boeing 747-8i of Lufthansa and the 747-8F freighters of many carriers.

The investigation of the GEnx engines began with the July 28th engine failure incident at Charleston, SC, USA, involving a Boeing 787 Dreamliner destined for Air India. Initial investigations suggested a fracture failure of the fan midshaft (FMS), first reported by Bangalore Aviation. While that investigation is still on-going, on August 31, the NTSB found similar indications on another GEnx-1B fitted on, a yet to fly, 787. The fan midshaft was removed from that engine for further inspection and examination. As a result of the investigative work to date, the NTSB has determined that the fan midshafts (FMS) on the GEnx engines fractured or cracked at the forward end of the shaft where the retaining nut is installed.

Exemplar image of GEnx Fan mid-shaft

The NTSB is also concerned about a loss of power on the GEnx-2B engine of a Boeing 747-8F cargo flight, operated by Air Bridge Cargo, at Shanghai, China, during take-off. The airplane had accelerated through 50 knots when the engine's low pressure rotor speed dropped. The pilot rejected the takeoff and returned to the ramp. Photographs of the low pressure turbine show damage similar to the GEnx-1B engine from the Charleston incident.

The urgent recommendations are: (1) (A-12-52) Issue an airworthiness directive to require, before further flight, the immediate ultrasonic inspection of the fan midshaft (FMS) in all GEnx-1B and -2B engines that have not undergone inspection, and (2) (A-12-53) Require repetitive inspections of the fan midshaft at a sufficiently short interval that would permit multiple inspections and detection of a crack before it could reach critical length and the fan midshaft fractures.

NTSB Chairman Deborah A.P. Hersman said
"The parties to our investigation -- the FAA, GE and Boeing -- have taken many important steps and additional efforts are in progress to ensure that the fleet is inspected properly," "We are issuing this recommendation today because of the potential for multiple engine failures on a single aircraft and the urgent need for the FAA to act immediately."
The engine manufacturer, GE, has developed a field ultrasonic inspection method to inspect the fan midshaft in the area where the fracture and crack occurred. This inspection can be done with the engine still installed on the airplane, thus saving operators a lot of money and downtime. To date, all in-service and spare GEnx-1B engines have been inspected. In addition, all GEnx-2B engines on passenger airplanes have been inspected. However, as per the the NTSB, approximately 43 GEnx-2B engines mounted on 747-8F cargo airplanes have not yet been inspected, and this is a concern on potential fan midshaft failures.

Read the full safety recommendations here.

The NTSB is still continuing its investigations, but these safety recommendations have the potential of snow-balling in to a major issue for national carrier Air India. After the Charleston incident, delivery of the first 787 for the carrier was delayed, with Indian aviation regulator, the DGCA, slow to grant safety clearance. At least two possibly three 787s were due to be delivered in rapid succession in the next few weeks. Will the carrier delay induction awaiting clarifications from the engine manufacturer?

Prudence demands they should. After all, engines can make up more than 30% the cost of the aircraft, and need to be beyond 100% reliable.

Share your thoughts via a comment.
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NTSB traces Air India Boeing 787 GEnx engine failure to fan mid-shaft fracture

The United States National Transportation Safety Board (NTSB) released an interim report on the progress of its investigation in to the failure of a General Electric GEnx engine on-board a Boeing 787 Dreamliner destined for Air India on July 28th last. The have traced the failure to a fracture on the forward end of the Fan Mid-Shaft.

Bangalore Aviation has exclusive obtained this exemplar image showing approximate location of the failure.
Exemplar image of GEnx Fan mid-shaft

The National Transportation Safety Board continues its investigation of the July 28, 2012 contained engine failure that occurred on a Boeing 787 Dreamliner during a pre-delivery taxi test in Charleston, South Carolina. A contained engine failure is a specific engine design feature in which components might separate inside the engine but either remain within the engine’s cases or exit the engine through the tail pipe. This design feature generally does not pose immediate safety risks.

Last week, the NTSB sent an investigator to the scene to gather information on the incident and subsequently launched a full investigation into the cause of the failure, led by NTSB Investigator-in-Charge, Mr. David Helson.

On August 1, 2012, a team of experts from the NTSB, FAA, Boeing and GE Aviation specializing in engine systems and metallurgy traveled to a GE facility in Cincinnati, OH to disassemble and examine the failed GEnx engine. GE is the manufacturer of the GEnx engine. The parties to the investigation have been extremely cooperative in assisting NTSB personnel in its review and assessment.

As a result of the investigative work to date, the NTSB has determined that a fan mid-shaft on the failed GEnx engine fractured at the forward end of the shaft, rear of the threads where the retaining nut is installed. The fan mid-shaft is undergoing several detailed examinations including dimensional and metallurgical inspections.

GEnx engine cut-away drawing not part of NTSB release.
The GEnx engine is a newly designed aircraft engine. It is a “dual shaft” engine, meaning that one shaft connects the compressor spool at one end to the high pressure turbine spool at the other end. A longer “fan shaft” connects the fan and booster in the front of the engine to the low pressure turbine in the back.

The cockpit voice recorder and flight data recorder, which is a combined unit on the 787 Dreamliner, was transported to the agency's Recorders Laboratory in Washington, DC for processing and readout. Both recordings captured the event and analysis is ongoing.

Moving forward, investigators will continue the detailed examination of the engine and metallurgical analysis of its components. The investigators have also begun reviewing the engine manufacturing and assembly records.

This investigation is ongoing. The information released today is factual in nature and does not include any analysis. Additional factual information may be released as it is developed.
Engine experts in India say that the main component carrying shafts inside an engine are an important part of the engine, but it is too early to say whether this fracture was caused due to materials flaw, a fault in manufacturing, or a design flaw. Depending on the reason for failure, it has the potential to become serious. However, the NTSB has not issued any recommendations yet. Boeing is due to deliver a GEnx powered 787 to Ethiopian Airlines early next week.
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How India's airline market lost its way

The following was posted as a guest post over at The Wandering Aramean, a great travel blog written by Seth Miller which also doubles as a travel tool site. Be sure to check his site out, and stay tuned, as we will have some guest content from him this week.

When India’s Jet Airways, Kingfisher Airlines, and SpiceJet all recently reported large net losses for Fiscal Year 2012 on the heels of Kingfisher’s steep downsizing in February and March, it came as a surprise to many people around the globe who considered India, and its burgeoning airline industry, one of the world’s greatest success stories. But as with India’s economic growth story (GDP growth in the first quarter of 2012 was a (relatively by Indian standards) anemic 5.3%), beneath the shiny veneer lies a tottering industry that must take drastic steps in order to ensure its future. But before one can explore the solutions to these issues, it is helpful to look at what exactly created the problems.
Any attempt to assign the collective failure in the Indian airline market to one specific reason is highly disingenuous; it took a special confluence of factors to create this mess. Some of the major factors are outlined below.
Lack of Capacity Discipline
The single biggest factor in the struggles of Indian airlines is their inability to properly manage capacity. It is said that the US airline industry, once a global loss leader, returned to profitability by following the “three Cs”: capacity cuts, consolidation, and charging for everything. But in India, the second and third clauses do not apply, and airline strategy planners have essentially ignored the first one.
To be sure, India’s aviation sector is growing at a robust pace. Demand measured in RPKs for domestic travel has averaged around 10% since April of last year. But India’s airlines have gone above and beyond this demand growth, adding capacity at exponential rates even as losses continued to mount. The graph below shows that for 9 out of the past 12 months, capacity growth in India far outstripped growth, a trend that has only recently begun to reverse as India’s airlines become increasingly cognizant of their dire financial situation and Air India and Kingfisher continue to shed domestic capacity.
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And to a large degree, the laws of supply (capacity) and demand have driven India’s losses. Standard supply/demand analysis tells you that when you increase the supply of something faster than the demand for that product is increasing, the price will then drop. What made the problem particularly acute was that this occurred right as there was a rise in fuel prices; the single largest input into the air travel product. Thus in effect, Indian carriers were driving down prices for their own products right as the price required for them to make money was appreciating. It’s not hard to see how this situation would cause an acute worsening of financial results.
Fuel
As was mentioned above, fuel prices were a killer for the Indian aviation market. From early 2010, fuel prices grew by more than 40%, lulled for a little bit in early 2011, before pushing back upwards again to $105/barrel (West Texas Intermediate). For India’s airlines, this rise in fuel prices was nothing short of disastrous, as it completely eroded their profitability (at India’s publicly traded carriers, the appreciation in nominal fuel costs was larger than the change in financial result – the loss could be primarily attributed to the sharp jumps in fuel costs. Domestic flying in India has razor thin margins during even low-oil periods, during a time of high fuel costs, profit margins quickly swing to loss ones.
image
And the problem is particularly troubling for India’s airlines thanks to a peculiarity of the market. Fuel composes between 40 and 50% of operating costs at all of India’s major airlines, higher than the figures at most major world carriers (those with older fleets typically spend somewhere in the mid 30s percentage wise on fuel, while LCCs and other carriers with younger fleets typically have fuel spend in the low 30s. The underlying reason for this cost disparity is Indian government policy.
Government Policy Failures
The policies towards jet fuel of the various levels of Indian government are a huge drag on Indian fuel costs. The tax burden on aviation turbine fuel (ATF) in India is sky high, nearly 35% on average. The problem starts at the national level where there is a double digit import duty on ATF. That’s then compounded on a state level by sales tax on the ATF that ranges from 3-4% in states like Tamil Nadu, to more than 20% in Karnataka. In addition to being an exorbitant levy, the state level ATF sales tax drives scheduling distortions, because the rates in two neighboring states can be widely disparate, making it more cost efficient for airlines to fly extra sectors and load fuel at airports. This adds extra time cost, delays, and congestion to the Indian air travel system. To give a specific example, Bangalore and Hyderabad are two cities in South-Central India, 283 miles apart. However, the sales tax on ATF is more than 15 percentage points lower in Andhra Pradesh (home to Hyderabad and incidentally, my ancestral home as well) than it is in Karnataka (home to Bangalore). Now most airlines with flights that terminate in Bangalore (given the relatively short distances involved in India’s domestic air transport system) will still have some fuel left over. What these airlines do, is instead of refueling entirely in Bangalore, they’ll only refill to the bare legal minimum before flying the short hop over to Hyderabad, where they refuel the entire tank. Then the aircraft will be re-routed into the airline’s system ex-Hyderabad, or in a lot of cases, flipped right back to Bangalore with a nearly full tank where it can fly routes to another Indian destination.
image
Beyond the problems with fuel, Indian government policy has failed the market in a broader sense, through misguided aviation regulations. The two most important are the prohibition of direct investment by foreign airlines, and
The Prohibition of Foreign Direct Investment and the 5 Year Rule
While India’s government finally appears to have approved 49% foreign direct investment (FDI) by foreign carriers in Indian airlines, the move might be too little too late. During the past year and a half, India’s airlines, especially Kingfisher Airlines, suffered from a lack of liquidity. While a lack of profits might have scared away normal investors, airlines are usually willing to accept a somewhat lower return on investment (ROI) in other airlines. For Kingfisher especially, inadequate funds might have been their biggest problem. In a vacuum excluding all interest and finance charges last year, Kingfisher’s financial results weren’t all that bad; and could have even been sustainable in the short term. And given the growing importance of India to the global airline system (especially amongst the alliances), it is likely that pre-crisis Kingfisher could have gotten access to the funds that it needed, perhaps from its future oneworld partners. And in a general sense, more liquidity for the Indian carriers would have boosted profitability across the market as a whole.
The 5 year rule meanwhile precludes Indian carriers from running international operations until they have been operating for five years (pretty self explanatory). While the explicit rationale behind this rule is ostensibly for safety reasons, the underlying driver behind the rule was to protect Air India’s lucrative near-monopoly on international routes from India. Once again, this rule played its biggest role in the downfall of Kingfisher. When Kingfisher was first started by the flamboyant, Branson-esque Vijay Mallya, a liquor baron, it was obvious that the new premium carrier had global ambitions. In a normal aviation market, such as the United States, Mallya’s airline would have simply had to pass all of the requirements to be certified as an airline. But in India, he would have had to have waited for five years. So Mallya instead decided to buy Air Deccan, a somewhat struggling low cost carrier (LCC) that had been in operation since 2003 and thus met the 5 year rule (possession of Air Deccan’s AOC would allow Kingfisher to fly abroad). This turned out to be a horrendous mistake, because Kingfisher Red (as the rebranded Air Deccan was known) had an unsustainable cost structure for an LCC and suffered from severe competition from more efficient LCCs like IndiGo and SpiceJet. Beyond the effects on Kingfisher, the 5 year rule has hurt Indian airlines in general. Because the 5 year rule was in place only for Indian carriers (while foreign carriers such as Emirates and Qatar Airways had free reign to essentially do whatever they wanted thanks to poorly negotiated bilateral between India and Dubai/UAE/Qatar – a whole different issue), carriers like Emirates managed to capture the lion’s share of lucrative traffic from India to the Gulf, Europe, and beyond.
Of course these policy failures are just drops in the bucket when compared to the single biggest factor; India’s erstwhile national carrier, Air India.
“The Air India Effect”
Air India has a very proud industry. It was the very first non-American airline to operate an all-jet fleet of Boeing 707s, and when Singapore Airlines was just starting out, they actually asked Air India to help design their service standards (shocking I know). But we’ve come a long way since those golden days, and today Air India is essentially a misshapen amalgamation of two disparate airlines (the “old” Air India that primarily flew international routes and Indian Airlines), that is mis-managed by the Ministry of Civil Aviation (MoCA).
Of course MoCA will want to protect its own business and so bilateral rights going disproportionately to Air India earlier this decade (via right of refusal) was a minor factor. But the bigger issue is the aforementioned “Air India Effect,” which is my euphemism for the blatant market manipulation practiced by the carrier. For political reasons, it is usually expedient for Air India to put out a ton of capacity, especially within India. Of course at Air India’s cost levels, the vast majority of this flying is unprofitable. If Air India were a private carrier, there would be a minimum level of prices beyond which they would not go (in microeconomic theory, this is the point where the price of an additional unit of product [capacity here] is equal to the marginal cost of producing another unit). But because Air India knows that the Government of India will not let them fail, it need not pay attention to these metrics, allowing it to dump excess capacity onto the market. If the routes are unprofitable, as almost every Air India route is, then MoCA and the GOI will be there waiting to bail out Air India. If Air India were a private carrier, they would have put out much less capacity over the past 5 years, and while I have yet to fully work out the demand elasticities, my model says that this excess capacity cost the Indian airline market billions of dollars in lost profits over the past 5 years.
Conclusion – Mismanagement and Hope for the Future
Even though I’ve outlined most of the major reasons above, I’d be remiss if I didn’t point out that strategy failures at the airlines themselves were part of the fall. Every airline in some form or the other has to deal with hostile factors outside of its control, but it’s how you respond to it that makes all of the difference. In the US, airline lost a cumulative $60 billion between 2000 and 2008, but after discovering the three C’s the US airline industry is powering non East-Asian airline profits. Meanwhile in India, airline execs largely ignored the signs calling for capacity discipline, and failed to make the tough choices in terms of being realistic with employees and cutting costs, while simultaneously pursuing failed business strategies.
And yet, there is hope for the future. India is troubled air market where the once largest domestic airline holds just a 5.4% market share and the national carrier is embroiled in prolonged industrial action with its most important pilot group. Yet during a time of slowing growth, a rapidly depreciating Rupee, and persistently high oil prices, it’s important to note that all of India’s airlines save Air India would have made money under the US ATF taxation system. Even in its darkest days, the Indian airline market is just a step away from profitability. Luckily, the fix for what ails India’s airlines is rather simple. Capacity (and cost) discipline is a must; and Jet Airways is a prime example. Since announcing their dismal results for fiscal year 2012, Jet Airways has begun purging their international network of unprofitable flying like Mumbai-Johannesburg in an attempt to shore up profitability; a smart idea to say the least. India’s government can make it easier on the airlines by coordinating a uniform national level sales tax on ATF, approving FDI, and abolishing the 5 year rule. And if by any miracle, Air India actually shrinks, then the recipe for reform in the Indian market is all but complete.
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Opinion: Bangalore airport should disclose full details of premature runway surface failure

Late last month, the airport operators of the Bengaluru International Airport announced a closure of the sole runway (09-27) starting from March 11, which will result in a suspension of all flight operations during the day, effectively shutting down the whole airport.
Runway 09 at Bangalore airport

The operators, Bengaluru International Airport Ltd. (BIAL), indicated the runway closure was being done to facilitate "runway maintenance work" on the advice of a world leading consultant who "monitor the airfield pavement surface and its performance".


The runway will be shut down in three phases. The first phase will see a full runway closure between 10:30 to 17:30 IST (5:30pm) from March 11, 2012 to April 3, 2012. Phases two and three will see partial runway closures. The shorter runway length will allow for operations of lighter aircraft (turbo-props or flights of shorter distances which will carry less fuel and therefore less weight). Full details are available in the AIP supplement.
For detailed information on runways, numbering, thresholds, loads, etc. read this article and its second part.
AIPS 2012 08 BIA Runway Closure

When The Hindu Business Line reported of a possible full scale runway closure the aviation community in Bangalore was abuzz on the possible reasons. A full scale runway closure is a major event, and for a runway to be closed for "maintenance" implies serious repairs. Serious repairs on a spanking new runway, at a new airport which has commenced operations less than four years ago, clearly implies something extra-ordinary.

A source with extensive knowledge of the Bangalore airport project, expressed extreme surprise on the timing of the repairs, as the runway surface was originally specified to last for at least twelve years.

Another source, also closely involved with the airport project, confirmed the failure, indicating the top layer of the 450mm thick runway has "been determined to be not as structurally strong as should be", calling the failure a "major civil engineering deficiency". This will require the complete top surface to be removed and re-laid. Sources cannot be named as they are not authorised to speak to the media.

The runway was constructured by former BIAL promoter and share-holder Larsen and Toubro, known as India's largest engineering and construction company. In 2005, Larsen and Toubro invested 55.54 crore for a 17% share in the airport project, which it sold in December 2009 for a hefty 1,100% profit to GVK Power and Infrastructure for Rs. 686 crore (Rs. 6.86 billion) and exited.

In its operations, BIAL behaves responsibly, performing runway maintenance with the regular consistency and efficiency of a finely tuned Swiss watch, but all these efforts appear derailed by this failure.

Failure began two years ago
The cracking of the runway surface apparently began in 2010, when the airport was just two years old and in the midst of the eonomic recession which saw domestic traffic levels plunge 20%.

Airport sources inform that BIAL brought in Applied Pavement Technology, Inc. (APTech), a world renowned engineering consulting firm specialising in airport pavement technology, to consult on the prematurely failing runway.

Repeated attempts to repair the runway over the last two years have not been succesful. It is learnt, that the degradation of the runway surface has reached such a serious level, that the effect of the monsoon on the pavement is no longer predictable, thus forcing BIAL to proceed with the maintenance work on a war footing so as to complete the activity before the onset of monsoons in May.

Commenting on this decision, an official spokesperson of BIAL said
“This is a proactive decision taken by BIAL. It recognizes its responsibility as the custodian of a key asset of the state and country and is committed to the safe and secure upkeep of this infrastructure. Passengers and airline operators top BIAL's priority list and we will work closely with them in our proactive efforts to ensure that any discomfort caused as a result of this closure remains minimal.”
Despite many requests, none of the BIAL spokespersons commented on the premature degradation of the runway surface, or its possible causes.

BIAL cannot escape blame
Regardless of the reason(s) for the runway failure, from an innocent oversight to malicious intent, none of them speak well to the reputation of Larsen and Toubro. The stain is even deeper considering the company is supposed to the best in India. In the same coin, while it is also a victim of sorts, BIAL cannot escape blame.

If it is a genuine omisson or mistake, one may even consider forgiving Larsen and Toubro. After all Bangalore was one of the first runways they ever built; but the three private promoters of BIAL were the leading icons in their respective areas of specialisation. As the "trusted custodian of a key national asset" where was this collective skill? Does it not speak to BIAL's oversight and monitoring at the time of construction? Is this a case of poor quality control? or were things taken on a little too much on trust just because the runway construction contractor was also a promoter?

Time to come clean
BIAL is an honourable organisation, and Larsen and Toubro could be doing the right thing in repairing the runway at its expense, but the inconvenience to be suffered by the various stake-holders of the airport -- airlines, staff, passengers, concession operators, industries, even taxi drivers, is all too real. The monetary and business impact is going to run in to crores and crores of Rupees with thousands of man-hours lost.

The citizens of Bangalore may not demand compensation, but answers they are.

BIAL should determine and fully disclose the precise reason(s) for the failure, the associated costs, and corrective action reports. If for no other reason, to ensure it does not happen again, and for the reputation of Public-Private-Partnership to be retained.
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