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Safety top priority for father of the jumbo

jumbo

The man who led the development of the jumbo, that opened the world for all, legendary Boeing engineer Joe Sutter had safety as the top priority.

Sutter led the team behind the company’s iconic Boeing 747, known affectionately as the “jumbo jet’’, and was responsible for pushing the boundaries of 1960s aerospace technology.

A native of Boeing’s birthplace, the US city of Seattle, and the son of a Slovenian immigrant, Sutter was born in 1921 and grew up on a hilltop overlooking the manufacturer’s plant.

“My friends all wanted to fly airplanes but I set my heart on designing them,’’ Sutter said in his book “747’’. “The futuristic flying machines I sketched as a boy would carry passengers in safety and comfort to the far continents, conquering oceans in a single flight. Little did I know I would grow up to realize these dreams.’’

READ Jumbo’s crazy and not so crazy interiors. 

A graduate of the University of Washington, Sutter started at the Boeing plant after serving in the US in Navy World War II and was courted by both Boeing and the Douglas Aircraft Company after the end of the war.

He initially accepted the higher Douglas offer but took what he thought was a short-term job with Boeing while his wife delivered the couple’s first child.

That job with Boeing’s small aerodynamic group working on the piston-powered Stratocruiser would be the start of a long and illustrious career that would see him work on many of the airline’s early jets.

“He personified the ingenuity and passion for excellence that made Boeing airplanes synonymous with quality the world over,’’ then Boeing Commercial Airplanes President Ray Conner said in a tribute sent when Sutter died in 2016.

“Early in Joe’s career, he had a hand in many iconic commercial airplane projects, including the Dash 80, its cousin the 707 and the 737.  But it was the 747 – the world’s first jumbo jet – that secured his place in history.

Joe led the engineering team that developed the 747 in the mid-1960s, opening up affordable international travel and helping connect the world.

“His team, along with thousands of other Boeing employees involved in the project, became known as the Incredibles for producing what was then the world’s largest airplane in record time – 29 months from conception to rollout.

Jumbo
Some of the early concepts of the 747. Credit: Boeing Historical Archives

It remains a staggering achievement and a testament to Joe’s “incredible” determination.”

At the time Sutter was designing what would become the jumbo jet,  the world was looking to supersonic travel with the Boeing SST and the Concorde as the future in aviation.

Giving life to the plane that changed the world was a challenge that brought Boeing, the world’s biggest aerospace company, the then-biggest engine maker Pratt and Whitney and the legendary Pan Am to their knees.

And while the speed with which the 747 was rolled out may be the stuff of legends, it was the one thing Sutter would have like to have changed,

He speculated the timetable was because of the closeness to the retirement of two legendary aviation figures: Pan-Am’s Juan Trippe and Boeing’s Bill Allen.

The two wanted the 747 completed in two-thirds the time ordinarily taken to develop an all-new jet and delivered by the end of 1969.

This put Sutter’s group under tremendous pressure but they rose to the challenge.

“In all my years at Boeing, I’ve never met a gang that pulled together as well as my 747 team,’’ he later recalled.

“We seemed to have the same can-do attitude that was even then putting Americans on the  moon.”

Not that the journey was without turbulence.

Pan-Am had originally asked for a double-decker plane but it’s management eventually accepted, after some persuasion, what was essentially a single deck plane whose cabin was twice as wide as any airliner that had ever flown.

Engines were also a problem for the 747 and Sutter was forced to head off lobbying for an unsuitable General Electric engine in favor of a more suitable powerplant from Pratt & Whitney.

Pratt’s JT9D engine was its first attempt at a high-bypass-ratio turbofan engine and was not without problems that included engine failures and surges.

There were also issues with the wing loading, eventually solved by twisting outer wings in what became known as the Sutter twist.

And the aircraft’s gross weight had also blown out from 550,000lbs to 680,000lbs before the 747s take-off weight was eventually redefined at  710,000lbs.

When the first 747, R A0001,  rolled out on a cold and overcast day in September 1968, it made global news and the crowd attending the vent gasped audibly and broke out in spontaneous applause.

“More important,” Sutter said in his book. “A  whole lot of bankers felt vastly relieved to see in the papers and on TV that Boeing had a real airplane to show for all that money we’d borrowed from them.

“In fact, this was the entire point of the rollout, which otherwise decidedly premature. Oh, our jumbo jet might have looked ready to leap into the sky but in reality, it was only 78 percent finished.’’

Boeing had wanted the aircraft to fly on December 17, 1968, to make the 65th birthday of the Wright brothers’ flight at Kitty Hawk in North Carolina.

That first flight would come on February 9, 1969, and Sutter described his quiet elation on the day.

“I saw Boeing’s new jet as 75,000 drawings, 4.5 million parts, 136 miles of electric wiring, five landing gear legs, four hydraulic systems and 10 million labor hours,’’ he recalled.

“In a few moments now, on an airfield 30 miles north of where I grew up dreaming of designing airplanes, we’d see whether all those pieces added up to a real flying machine.’’

As the plane took to the skies and performed a shallow turn, Sutter found himself unable to say anything.

Despite reassurances the plane was “flying beautifully’, it was not until it descended to the runway “with the stately majesty of an ocean liner”, flared gently and touched down smoothly that Sutter relaxed.

“That moment was the biggest thrill of the day,” he said. “All my worries evaporated and I knew we had a good airplane. I took a grateful breath, happy to  the core of my being.”

Ju

Throughout all this, one thing Sutter was never prepared to compromise was safety.

Innovations included a decision to take redundancy on the 747 to new levels with arrangements such as four separate and independent hydraulic systems.

The most comprehensive certification program performed to that time kept five 747 test aircraft flying seven days a week over 10 months of flight testing.

“My team and I would be introducing the biggest airplane in the world,’’ Sutter said in his book. “Here was also our chance to make it the safest.’’

The jumbo jet would become the Queen of the Skies, selling more than 1500 units and still in production today.

Sutter was always was modest about his role. “I was the only qualified person available,” he said in a 2009 interview with AirlineRatings. “All the smart guys — Maynard Pennell, Bill Cook, Bob Withington, and many others — were tied up on the SST while Jack Steiner was heading the 737 program.”

The 747 was from the outset designed to be converted to a freighter as the superseded model was relegated to cargo routes. “That’s what Boeing’s marketing people thought,” Sutter said. “They estimated we’d probably sell 50 or so for passenger use.”

Sutter remained active with Boeing long after his retirement and continued to serve as a consultant as well as an ambassador for the company.

“By then his hair was white and he moved a little slower, but he always had a twinkle in his eye, a sharp mind and an unwavering devotion to aerospace innovation and The Boeing Company,’’ Conner said in his tribute.

Airbus A330-900 certified by EASA

Airbus A330-900 EASA certification

The Airbus A330-900 has received its type certification from the European Aviation Safety Agency ahead of the delivery of the first aircraft to TAP Air Portugal in coming weeks.

TAP’s aircraft served as a demonstrator during a global tour and joined two flight test aircraft in a certification program involving about 1400 flight test hours since the type first flew on October 17, 2017.

Airbus expects the corresponding certification from the US Federal Aviation Administration to follow soon.

Powered by Rolls-Royce Trent 7000 engines, Airbus claims the A330-900 has the lowest seat-mile cost in the 300-seater range.

The European manufacturer says the efficient Trent 7000s,  a new optimized wing with new sharklets and the use of lighter composite materials bring a reduction in fuel consumption of 25 percent compared with older generation aircraft of similar size.

It also benefits from a common pilot rating with the A350 XWB and new data connectivity features aimed at helping operators predict potential issues before they become a problem.

The TAP aircraft will feature the Airspace by Airbus cabin with newly designed sidewalls and fixtures, larger overhead storage, advanced cabin mood lighting and the latest in-flight entertainment and connectivity.

Launched in July 2014, the neo is a refinement of the popular A330 in service since 1994.

READ Airbus A330neo takes off in turbulent times.

Airbus has offered A330neo in two versions with 99 percent commonality, the A330-800, due to make its first flight in coming weeks, and A330-900.

The manufacturer has 224 firm orders for the -900 but the future of the A330-800 is in doubt after its sole customer, Hawaiian Airlines, canceled its order for six aircraft in favor of Boeing’s 787-9 Dreamliner.

Airbus also lost a campaign to sell the A330neo to American Airlines after it was unwilling to match the price Boeing offered.

However, AirAsia reconfirmed its commitment to 66 of the A330neo at this year’s Farnborough Air Show and placed an order for an additional 34,  rounding up to an even 100.

Former Airbus chief commercial officer Eric Schulz conceded on the sidelines of June’s International Air Transport Association conference in Sydney that the route proving was when the rubber hit the road.

“And so far we are extremely satisfied with the performance of the plane .. after the first phase of flight tests,” he said. “In terms of delivery, we are working very closely with TAP but we are within the last delivery dates we made public before so there is no change.

“If anything the program is doing quite well now.”

On the question of demand, Schulz acknowledged Airbus had suffered two defeats in a row with Hawaiian and American and the losses were unfortunate.

“In this particular case, I am not particularly anxious about the future of the 330neo,” he said. “Just here over the last three days I’ve seen many, many customers very interested about the neo and we have deals in process.

“I am quite hopeful that we will continue to find our place in the market.”

Crushed phone ignites after Qantas passenger ignores safety video

qantas vodka

It isn’t rocket science but it seems some people are still having trouble grasping the simple instruction to call a flight attendant if they lose their phone in their seat.

A business class passenger on a Qantas Airbus A380 flight from Los Angeles to Melbourne has become the latest to ignore the instruction and cause a furor by crushing their mobile phone moving the seat in an attempt to retrieve it.

SEE our video “Dispelling the myths about flying”.

The aircraft was about two hours out of Melbourne Wednesday when the smell of burnt rubber reportedly wafted through the cabin and flight crew were seen heading to the business cabin with fire extinguishers.

The cabin crew contained the smoking phone and the pilot decided to continue to Melbourne after a conversation with the airline’s operations center.

“Our crew are trained to handle these situations and the crew onboard followed all the correct procedures,’’ a spokesman said.  “This incident shows why we ask passengers to seek help from our cabin crew in retrieving their mobile phones.”

READ Passengers continue to ignore device fire danger

Not following the correct procedures or the advice given on every flight during the safety video can be dangerous.

Australia’s Civil Aviation Safety Authority estimates the average Australian passengers travel with three to four personal electronic devices on their person with another one to two packed in checked baggage.

“While rare, there have been incidents of malfunctioning/damaged lithium batteries in recent years with the most common cause being smartphones and their batteries being crushed in passengers’ seats,’’ CASA said.

Crushing a phone is not the only reason a  battery might ignite: others include electrical shorting, rapid discharge, overcharging, a manufacturing defect, poor design or by simply being dropped.

The more severe cases can result in a “thermal runaway”,  a reaction within the battery causing internal temperatures and pressure to rise at a quicker rate than can be dissipated.

“Once one cell within a battery goes into thermal runaway it can produce enough heat to cause adjacent cells to sympathetically react,’’ CASA warns. “ This can produce  smoke, fire and fumes that can repeatedly flare up as each battery cell in turn ruptures and releases its contents.”

One of Australia’s first reportable lithium battery events occurred in November 2011 when a Regional Express passenger’s iPhone started emitting smoke as ta Lismore-Sydney flight landed.

The overheating was traced to a loose screw from an unapproved screen repair causing a short circuit.

Perhaps the most widespread impact of lithium battery fires came when manufacturer Samsung was forced to discontinue the Galaxy Note 7  in 2016 after it was banned by airlines globally for safety reasons.

CASA tells airlines to educate passengers on how to use and stow their devices and not to use mechanical or electrical seat functions when a device is lost in a chair.

 

 

NTSB calls for better pilot briefings after Air Canada near disaster

Air canada San Francisco NTSB NTSB
Source: NTSB

The head of the US National Transportation Safety Board has slammed the way flight operations information is presented to pilots as “garbage”  at a public hearing into a near catastrophe involving an Air Canada flight landing at San Francisco.

The  Air Canada A320  carrying 140 passengers and crew from Toronto  was cleared to land on San Francisco International Airport ’s runway 28R on July, 2017.

The experienced flight crew instead lined up on a crowded parallel taxiway due to what investigators determined was a lack of awareness.

Four aircraft — an  Airbus A340, two Boeing 787s and a Boeing 737 — were on the taxiway awaiting takeoff clearance on July 7, 2017, when the pilots mistook if for the runway.

After flying over the first aircraft on the taxiway at 100ft above ground level  the plane dropped as low as 59 feet  — barely above the 56ft height of a Boeing 787 tail — before it began to gain height.

The aircraft performed a go-around and returned to land safely but experts said it could have been one of the worst catastrophes in aviation history.

The NTSB found the crew was unaware a parallel runway had been closed due to their “ineffective review of notice to airmen (NOTAM) before the flight and during the approach briefing”.

Contributing to this was the flight crew’s failure to tune to the instrument landing system (ILS)  for backup lateral guidance as well as their firm belief they were on the right course, fatigue and breakdowns in crew resource management.

Also contributing was  “Air Canada’s ineffective presentation of approach procedure and NOTAM information”.

READ our ratings  for Air Canada

“Although the notice to airmen about the runway 28L closure appeared in the flight release and the aircraft communication addressing and reporting system message that were provided to the flight crew, the presentation of the information did not effectively convey the importance of the runway closure information and promote flight crew review and retention,’’ the NTSB said.

The NTSB called more effective presentation of flight operations information to encourage pilots to review it and remember what it said.

NTSB board members complained at the hearing that NOTAMs were an archaic system full of useless information that hid important details.

“(NOTAMs) are written in a language only a computer programmer can understand,” US media quoted NTSB chairman Robert L. Sumwalt as saying. “NOTAMs are just a bunch of garbage.”

Sumwalt said the mistakes identified in the report highlighted the need for a further review of approach and landing procedures.

“This event could very easily have had a catastrophic outcome,’’ he said. “The recommendations issued as a result of this investigation, if implemented, will help prevent the possibility of a similar incident from occurring in the future.”

Other recommendations issued to the US  Federal Aviation Administration and Transport Canada addressed issues such as the need for aircraft landing at primary airports within class B and class C airspace to be equipped with a system that alerts pilots when an airplane is not aligned with a runway surface.

The NTSB also called for a method to more effectively signal a runway closure to pilots when at least one parallel runway remains in use, and modifications to airport surface detection equipment systems to detect potential taxiway landings and provide alerts to air traffic controllers.

The FAA, which says it is looking at simplifying NOTAMs, modified night time landing procedures at San Francisco as a result of the incident.

 

Seat pitch shrinks on Air New Zealand’s new A321neo

Air New Zealand seat pitch
Air New Zealand's new A321neo. Photo: Air NZ

Air New Zealand’s first A321neo will enter low-cost carrier territory with some seats offering a Hobbit-sized 29-inch (73cm) pitch when it enters the fleet in mid-November.

The Kiwi carrier has ordered 13 Airbus neo aircraft — seven A321neos and six A320neos — to replace its existing fleet of A320s and another seven A321neos are on order for anticipated domestic growth.

The planes have a combined list price of $NZ2.8 billion and the new technology A321neos will help deliver fuel savings and efficiencies of at least 15 percent compared to the planes they replace.

The international A320neos will have 165 seats on board compared to the 168 on the current international aircraft, which feature a seat pitch of 30 to 34 inches. Seat pitch is the distance between a point on a seat to the same point on the seat in front.

The A321s will have 214 seats with a seat pitch ranging from 29 inches to 33 (83cm) inches.

But the airline says the slimline design and curved design of the A321neo seats means passengers “sink further into the seat back creating up to 7 percent more usable space when compared with the equivalent pitch on the existing fleet”.

The middle seat will also be 3cms wider and the aisle and window seats 1cm wider. This will boost the aisle and window seats to the Airbus standard of 18 inches from the narrow 17-inch seats on the existing A320s.

Other enhancements in the cabin include 25 percent more overhead locker space, a new Android-based inflight entertainment system with a 10-inch screen, high power USB charging points and Wi-Fi connectivity.

The tight seats kick in from row 18 rearwards on the left side of the cabin as you face towards the nose, although there are exit row seats and a couple of rows of seats with a pitch of just under 30 inches (76cm).

Most of the seats along the starboard side are 30 inches or above but, again, there are a couple of rows of 29-inch seats.

The more spacious 32-inch (81cms) and 33-inch (83cm) seats are at the front of the plane  (Note: The conversion to seat pitches in inches is rounded up to the nearest inch.).

The 29-inch seat pitch means the Kiwi carrier has gone where even some major US carriers have vowed not to go and into seat pitch territory normally occupied by low-cost carriers.

READ: US seat legislation may not mean more legroom.

But Air New Zealand Chief Executive Officer Christopher Luxon said the airline had extensively tested the neo inflight experience with customers to ensure it could incorporate their feedback “while meeting regulatory and operating requirements’’.

This had left it confident it would deliver an inflight experience passengers would enjoy.

“Australia and the Pacific Islands are a vitally important part of our Pacific Rim network,’’ he said.

“We operate up to 240 services each week with our Airbus narrow-body aircraft.

“These new aircraft are key to enabling us to grow our short-haul network while offering our customers a great inflight experience.’’

A second A321neo is also expected to enter service in November and the airline’s first A320neo is scheduled for February, 2019.

The remaining aircraft will follow at intervals until late 2019, while the additional A321neos for the airline’s domestic network are expected to be delivered from 2020 to 2024.

How Boeing’s supersized 747 factory almost ended up in California

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Aerial View of Everett Boeing; View from South to North; includes 777X Wing Building;

The world’s biggest building and home of the iconic Boeing 747, which rolled out 50 years ago this week, could well have ended up in California.

Boeing in the 1960s did not have a factory big enough to house its new jumbo jet so a search began for a suitable site to build what would turn out to be the mother of aircraft plants.

A key factor was an airport with a long runway capable of handling the new plane and three potential sites were evaluated while the 747 was still in the early design phase.

One was Snohomish County Airport, a former military base better known as Paine Field and located 30 miles north of Seattle near what was then the sleepy lumber town of Everett.

A second was past Tacoma, 32 miles southwest of Seattle, at a site adjacent to McChord Air Force base.

READ: Singapore Airlines takes delivery of New York nonstop A350.

The third was at Walnut Creek, California, in the East Bay region of the San Francisco area.

Boeing had recently lost the C-5 program to Lockheed and the thinking was that siting the factory in California could offset the political advantages of competitors.

Supporters of the Walnut Creek site pointed to the fact that Douglas, North American Rockwell, General Dynamics, Northrop, and many other aerospace firms were based in California.

“Some very senior Boeing people were pushing very hard to site our 747 factory there to benefit from that state’s greater political clout in Washington, DC,’’ Boeing engineer Joe Sutter said in his book “747”.

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The original 747 building in 1970 with three production halls. Many of the 747s on the flight line are awaiting engines because of modifications required to meet performance issues. Credit Boeing Historical Archives

Sutter argued against the California site on logistical and cost grounds when asked his opinion at a committee meeting to discuss the site.

“Given this opening, I told ’em point-blank that I thought it would be an unmitigated disaster,” Sutter wrote.  “If 747 production were sent down there, communications would slow, coordination would suffer, costs would rise, our overall logistical challenges would increase, and there was no way in hell that we would meet our schedule commitments to Pan-Am.”

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Another 747 comes together at Everett. Credit: Boeing Historical Archive

Sutter’s view provoked an angry reaction from the Walnut Creek supporters but to his immense, relief Boeing decided at the start of 1966 to build its new plant at Everett.

It would prove, he recalled, a herculean task which required more soil to be removed from the 700-acre site than was shifted for the Panama Canal and Washington states Grand Coulee Dam combined.

The $US200 million project involved 2500 construction workers toiling in endless rain and mud to erect the 200 million cubic foot  (5.66m cubic meter) building.

An engineering feat in its own right, the building’s immense size  — it is the world’s biggest in terms volume — made it a landmark and a major tourist attraction for the region.

“So big was it that Boeing workers would sometimes see clouds forming inside it,’’ Sutter said.

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The Everett factory in the early 1980s with the additional productional hall built on at the right with the orange door. Credt: Boeing Historical Archives

The factory would be enlarged to accommodate production of the 767 in 1980 with one extra production hall and was expanded again in 1993 with two additional halls to build the 777.

Today, the world’s biggest building by volume encloses  472 million cubic feet of space over 98.3 acres and you could fit 911 basketball courts inside.

At almost two-thirds of a mile (more than 1km) long and a third of a mile wide, employees often use bicycles to get between jobs.

The massive production facility has six doors, each the size of an American football field and a giant canvas for artwork depicting the company’s planes.

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Two Qantas 747-400ERs come together. Credit Geoffrey Thomas

Twenty-six  26 overhead cranes cruise on 72 kilometers of networked tracks and these make 45,000 lifts a month to support the building of approximately 20 planes a month.

Yet the main assembly building is just part of a massive industrial complex that includes three huge paint hangars, sprawling flight lines, a plane delivery center that is as big as an airport terminal, office blocks and a new wing assembly plant.

The Everett campus is the workplace for 30,000 people, produces 25,000 meals a day from 20 cafeterias and its area is bigger than Disneyland — with 12 acres of parking left over.

In many ways, it is indeed a magic kingdom where the world’s largest aerospace company Boeing has produced about  5000 widebody planes – the 747, 767, 777 and 787 since 1968.

The Everett facility in the 1990s with two extra production halls added for the Boeing 777. Credit Boeing Historical Archives

It is one of the most popular tourist attractions in Washington State. Boeing started tours of the factory when it was building the first 747 and since then more than 3.5 million people have seen the facility.

The  Everett campus is now building the company’s newest plane, the Boeing 777X, a revamp of the widely used 777.  A plant to build the 777X’s composite wings increases the factory floor space on the campus a further 25 percent.

Read tomorrow “Safety was a top priority for the father of the 747.”

 

US airline seat legislation may not mean more legroom

seats US laws FAA legroom

US legislation requiring the Federal Aviation Administration to draw up regulations covering minimum airline seat dimensions has been given a bipartisan tick but passengers shouldn’t hold their breath waiting for a more comfortable ride.

The House and the Senate reached consensus on a 1200-page bipartisan bill to reauthorize Federal Aviation Administration funding for five years over the weekend and one of the provisions requires the FAA to set minimum legroom and width limits for airline seating.

The FAA will then have a year to develop regulations on minimum standards for economy seating, including seat pitch (the space between a seat and the seat in front of it), width and length.

But the legislation does not specify what this should be other than to say they would be minimum dimensions “that are necessary for the safety and health of passengers”.

Nor does it give any indication how the rules would relate to cramped seating already in place.

There is some speculation The FAA  could establish a floor for seat pitch as low as 28  inches and a minimum width of 16.5 inches, dimensions that would still be cramped for most people.

This FAA was forced to visit the issue after a federal court judge ordered concerns about what she described as “the incredibly shrinking airline seat’” during a case brought by consumer group Flyers Rights.

Flyers Rights had argued that narrower seats and closer seat spacing were “endangering the safety, health and comfort of airline passengers.”.

But in its response, the FAA indicated it did not have a problem with seat pitches as low as 27 inches, although it doubted airlines could sell a configuration that tight.

The lowest seat pitch currently is about 28 inches but many legacy carriers offer 31 to 32 inches.

The US regulator told Flyers Rights in a letter that it had no evidence of an immediate safety issue requiring a change to existing rules.

It said that nothing in letters or submissions provided by the consumer organization “demonstrated that current seat dimensions (width and pitch) hamper the speed of passenger evacuation, or that increasing passenger size creates an evacuation issue.”

Airline chiefs are opposed to outside interference in how they configure their cabins and say people who want more space can buy it.

READ: Economy class crunch, airline chiefs warn against legroom regulations.

However, the bosses of two major carriers, American and Delta, pledged recently not to make seating any tighter than it already was.

Some other changes in the FAA Bill may have more impact on passengers.

It prohibits passengers from being involuntarily removed from flights once they’ve passed the gate. This provision was put forward in response to the infamous incident where a  doctor was dragged screaming from a United flight in Chicago.

Airlines will also still have to advertise the entire price of a ticket, including taxes and charges, and regulators will now be able to determine whether airlines are fibbing when they tell passengers that flights have been delayed or canceled because of weather.

But successful lobbying by airlines means a proposal limiting baggage and reservation change fees was dropped, although carriers must now refund passengers for services for which they paid but did not receive.

Other changes cover the potential return of supersonic flights by allowing reduced sonic booms over land and the ability of passengers traveling with small children to check strollers.

One of the more bizarre provisions makes it against the law to place a live animal in an overhead storage compartment.

This was prompted by anger over the death in March of a 10-month-old French Bulldog after a flight attendant required it to be placed in an overhead bin.

 

The 747, Queen Of The Skies, turns 50

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The 747 just before its roll out.

Fifty years ago this week on September 30, 1968, the Queen of the Skies that made travel affordable for all, the Boeing 747, rolled out into the Seattle sunshine.

But its birth was to bring dark clouds to the leaders in commercial aviation at the time and almost bankrupted all three.

SEE our video “Dispelling the myths about flying.”

Ironically, the 747 wasn’t supposed to carry passengers for very many years as the world looked to supersonic travel with the Boeing SST and the Concorde.

Boeing has now sold 1,568 747s and it’s still in production with the latest model still turning heads.

But giving life to the aircraft that changed the world was a challenge that brought the world’s largest aerospace company, Boeing, the then biggest engine builder Pratt, and Whitney and the legendary Pan Am to their knees.

READ: New interior images of the 777X show a new level of comfort

In the late 60s, Boeing’s resources were stretched to the absolute limit as its engineers grappled with the complexities of its US government sponsored 2707 supersonic transport, which was eventually scrapped by Congress on May 20, 1971, despite commitments for 115 from 25 airlines.

At the time the 747 was considered only an interim solution before the world’s air routes were taken over by supersonics but fortunately, Boeing had appointed Joe Sutter, a brilliant young designer, to the project and he was to father the classic of the jet age.

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Joe Sutter in front of the first 747. Credit Boeing Historical Archives colorized by Benoit Vienne

Mr. Sutter was extremely modest on this role.

“I was the only qualified person available. All the smart guys, Maynard Pennell, Bill Cook, Bob Withington, and many others were tied up on the SST, while Jack Steiner was heading the 737 programs,” Mr. Sutter said in a 2009 interview with the author.

The 747 was designed at the outset to be a freighter as everyone thought the 747 would be relegated to cargo routes.

“That’s what Boeing’s marketing people thought; they estimated we’d probably sell 50 or so 747s for passenger use,” said Mr. Sutter.

The 747 was a mass travel dream of Pan American World Airways founder Juan Trippe and Boeing chief Bill Allen.

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Boeing’s Bill Allen (Left) and Pan Am’s Juan Trippe. Credit Boeing Historical Archives colorized by Benoit Vienne

Mr Trippe had started mass travel in 1948 when he introduced economy class onto 70 seat DC-4s.

But the 747 was far, far bigger. It would carry over 350 – almost double the Boeing 707 – and would slash fares.

It is impossible to find anyone who recalls if there was a definitive business plan for the 747. But traffic was booming for the airline industry which had enjoyed growth of 15 percent a year through the early 1960s as passengers flocked to jet aircraft.

Mr. Trippe was a man on a mission.

He wanted to make travel affordable for everyone and he believed that the 747 with the new high bypass turbofan engine could do just that.

Pan Am ordered 25 but most airlines were terrified of the jumbo’s size. Qantas ordered 4, British Airways 6, while many airlines just ordered 2 or 3 just to stay in the jumbo race.

747

However, the trickle of orders wasn’t the major problem it was the 747’s weight.

Initially, it was to weigh 250,000kg but this leaped to 322,000kgs by the time it flew because of design changes impacting range, altitude, speed, and fuel burn. A solution, to run the engines at higher temperatures to give more thrust, was found and within six months of entering service, the jumbo was performing at acceptable levels.

Despite the many problems encountered in its manufacture, the birth of the 747 was an amazing feat. Pan Am took delivery of its first aircraft just 3-and-a-half years after its order was placed and that included a 10-month flight-test program.

Because the 747 was so big airlines splashed out with lounges. There was the upper deck lounge and many had lounges at the back of economy class. However a Boeing proposal for a lower deck lounge – called the Tiger Lounge, because of the fabric design used in the mock-up never made it.

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The 747 gleams in the Seattle sun

The spacious age, however, was short-lived with airlines responding to a demand for cheaper and cheaper travel in the late 1970s by adding more seats.

There have been many variants of the superjet. The upper deck was stretched for the -300 model and a modified wing and bigger engines added for the longer range -400 version.

The 747 was also shrunk for the SP (Special Performance) model that was the first aircraft to be able to cross the South Pacific from the US to Australia non-stop.

Finally, the 747 itself was stretched to create the 747-8, which features wing changes and 787 engines.

Today the 747 is still the Queen of the Skies to many and for billions of passengers, it is the plane that enabled them to see the world.

Tomorrow AirlineRatings.com looks at the Boeing’s jumbo kingdom.

Pilot in fiery shopping center crash failed to check controls

Pilots shopping centre crash Melbourne
Photo: Seven News

The pilot of a plane involved in a fiery fatal crash in a Melbourne shopping center did not detect that a rudder setting that caused the plane to veer to the left was engaged prior to take-off, investigators have found.

Pilot Max Quartermain and four American tourists died when the Beechcraft B200 King Air aircraft crashed into a shopping complex and exploded at Melbourne’s Essendon Airport in February, 2017.

The four US nationals —Greg DeHaven, Russell Munsch, Glenn Garland and John Washburn — were on a golfing trip to King Island off the coast of Tasmania.

An Australian Transport Safety Bureau report found the aircraft took longer than expected to take off and was seen to yaw to the left after it lifted off.

It entered a shallow climb followed by a substantial left sideslip prior to it descending and hitting the shopping center.

Investigators found the pilot, who sent out a Mayday as the aircraft descended, did not detect that the rudder trim was in the full nose-left position prior to take-off.

Rudder trim is used to adjust a small panel on the rudder to allow coordinated flight without the pilot having to constantly apply pressure to the controls.

“The position of the rudder trim resulted in a loss of directional control and had a significant impact on the aircraft’s climb performance in the latter part of the flight,’’ The ATSB said.

Investigators said it was likely Quartermain was applying right rudder pedal in an attempt to compensate for the yaw induced by the incorrectly set runner trim.

‘While the ATSB was unable to quantify the rudder pedal forces required to overcome the mis-set rudder trim, when tested in a B250 class-D simulator, the forces could only be countered by the pilot for a short period of time,’’ it said.

Investigators also found Quartermain did not have appropriate pre-flight check systems in place and this “increased the risk of incorrect checklists being used, incorrect application of the aircraft’s checklists, and checks related to supplemental equipment not being performed.”

They also noted the aircraft’s cockpit voice recorder did not record the accident flight due to a tripped ‘impact switch’, which was not reset prior to the accident flight.

“This deprived the investigation of potentially valuable recorded information,” it said.

The aircraft was operated above the maximum take-off weight on the day of the accident, although this was not seen to have influenced the crash.

The report found that the presence of the building struck by the aircraft did not increase the severity of the consequences of this accident. In the absence of that building, the aircraft’s flight path would probably have resulted in an uncontrolled collision with a busy freeway, with the potential for increased ground casualties.

Pilots shopping center Melbourne
Photo: ATSB

It also raised questions about buildings in the retail precinct that exceeded the airport’s obstacle limitation surfaces.

“The ATSB also found that the presence of the building struck by the aircraft did not increase the severity of the consequences of this accident,’’ it said. “In the absence of that building, the aircraft’s flight path would probably have resulted in an uncontrolled collision with a busy freeway, with the potential for increased ground casualties.”

In its safety message, The ATSB emphasized the importance of checklists and flight check systems.

“The ATSB encourages all pilots, no matter what your experience level, to always follow the appropriate checklist thereby preventing accidents like this in the future,” chief commissioner Greg Hood said.

“In addition to the checklists, The ATSB also considers that pilots need to carefully consider their decision making, particularly during critical phases of flight such as take-off.

“If anything is abnormal in relation to the operations during take-off, considering aborting that take-off.”

The crash is controversial because  Quartermain about 18 months previously had been involved in a near collision that took him within a few hundred feet of another plane near Victoria’s Mt Hotham.

READ:  Report confirms shopping center pilot in 2015 near collision.

The Mt Hotham report found Quartermain ran into difficulties as he approached the airport and had difficulties operating the GPS and autopilot.

It said “an unexpected reduction in the level of flight automation” and an increase in workload affected Quartermain’s ability to follow the established tracks such as the published approach and missed approach. He also did not communicate his position accurately to the other aircraft or air traffic control.

The pilot underwent flight testing by a Civil Aviation Safety Authority delegate and then by a flying operations inspector, who recommended remedial training before undergoing a further flight test.

He was deemed proficient and competent to resume operations after the subsequent flight test.

Air New Zealand to axe Vietnam, suspend Tokyo flights

Ai rNew Zealand trans-Tasman

Air New Zealand will stop flying to Vietnam next year and is suspending flights to Tokyo’s Haneda Airport to protect itself against “unexpected disruptions”.

It will also reduce frequencies to Argentina and its recently opened route to Tapei as it grapples with a global problem affecting Rolls-Royce Trent 1000 engines powering its Boeing 787 Dreamliners.

The airline has been flying to Vietnam on  a seasonal basis since 2016 and had already reduced the frequency from three flights to two a week.

The changes were outlined in a letter from AirNZ boss Christopher Luxon to customers apologizing for what he labeled “an incredibly challenging year”.

Luxon acknowledged that many of the airline’s customers had experienced disruptions and delays, rescheduled flights, unexpected aircraft replacements and overcrowded lounges.

While there had been unexpected problems with weather and a ruptured pipeline, Luxon said the biggest issue had been the unscheduled maintenance issues with the Rolls-Royce engines powering its Boeing 787 Dreamliner’s.

Air New Zealand has been caught up in a problem with Trent 1000 package C engines that has caused increased checks and maintenance affecting airlines worldwide.

READ: Trent troubles to cost Rolls-Royce at least £1 billion.

“This has meant that at any time up to five of our 13 787 Dreamliners must be grounded while the engines are serviced in Singapore,’’ Luxon said.

“This has placed significant pressure on our whole interconnected network of over 3,500 weekly flights and I will be meeting with Rolls Royce management in London in a few weeks to further seek personal reassurance that all is being done to get our affected engines back in service as soon as possible.”

The Kiwi carrier has leased three aircraft to offset the Dreamliner engine problems and staffed them with Air New Zealand crew, food and beverages.

“We will also further protect ourselves from unexpected disruptions by stopping flying to Vietnam next year, suspending our services to Haneda in Tokyo and slightly reducing our frequency to Argentina and Taipei,’’ Luxon said.

“These are big decisions to make but are vital to free up capacity and let us concentrate on delivering a better experience across the board.”

Air New Zealand has also been struggling with increased traffic at airports due to what Luxon said was underinvestment by airport operators as well as long wait times at its call centers.

The airline is adding 80 additional call center staff to cope with the wait times and is talking to airport chief executives to try and accelerate needed improvements.

It had also invested in a lounge redevelopment program in Auckland and has upgrades planned at Wellington and several regional airports, Luxon said.

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