Individually Owned: 150,657
Corporate Owned: 137,281
Aircraft Accident/Incident Report
Lake Michigan, --
Wednesday, October 20, 2004 20:29 CDT
NTSB Narrative Summary Released at Completion of Accident
The Boeing 747-132, operated as an unscheduled domestic cargo flight under 14 CFR Part 121, was climbing through 15,000 feet mean sea level when the number one engine separated from its forward and aft engine mounts resulting in substantial damage to the airplane. The flight diverted to an alternate airport where it landed without further incident. Examination of the engine revealed an uncontained separation of an approximately 180-degree arc of the second stage turbine disk rim. The missing section of the rim coincided with circumferential rub marks on the second stage turbine disk that corresponded to rub marks on the rear inner rails of the second stage turbine vanes. The rubbed areas of the disk and vanes did not exhibit heat cracking consistent with a relatively long time period of rubbing relative to a sudden disk-to-vane contact. The fan rotor bearing did not exhibit rotational distress. The engine did not exhibit any evidence of a blade separation, case rupture, or any other uncontainment. The second stage retaining bolts are coated with a baked-on antiseize compound, FelPro C-200, during manufacture. Metallurgical exam of the second stage turbine bolts revealed cracking in the head-to-shank fillet radius and the presence of silver consistent with Silver Goop. Silver Goop is an anti-seize compound not authorized by the engine manufacturer for use in the high-pressure turbine area but is authorized in the low-pressure compressor area due to the catalytic properties of silver with wet FelPro C-200 resulting in a corrosive mixture that can contribute to bolt fractures. The induced loads from the second stage disk rim separation were estimated to have been 3.6 - 6.6 times greater than to those induced by a fan blade separation. The accident operator purchased an engine as-is and that according to maintenance records was not preserved when it was removed from an airplane belonging to another operator about 5 years prior to the accident. The high-pressure turbine (HPT) module was removed from this engine and installed on one of the accident operator's other engines prior to it being removed and then installed on the accident airplane engine. The accident operator's examination of the HPT was limited to a visual inspection that would not have detected a vane shift or ascertained the integrity second stage turbine vane assembly.
NTSB Probable Cause Narrative
The number one engine separated from the airplane during climb due to the uncontained separation of a portion of the second stage turbine disk rim after the second stage turbine vanes contacted the disk. The second stage turbine vanes contacted the second stage turbine disk due to the operator's inadequate inspection of the high pressure turbine module and the improper repair of the module by unknown maintenance personnel.
Event Information
| Type of Event | Accident |
| Event Date | 10/20/2004 |
| Event Day of the Week | Wednesday |
| Time of Event | 2029 |
| Event Time Zone | Central Daylight Time |
| Event City | Lake Michigan |
| Event State | -- |
| Event Country | -- |
| Zipcode of the event site | -- |
| Event Date Year | 2004 |
| Event Date Month | 10 |
| MidAir Collision Indicator | No |
| On Ground Collision occurred ? | No |
| Event Location Latitude | 420432N |
| Event Location Longitude | 0865202W |
| Event Location Airport | -- |
| Event Location Nearest Airport ID | -- |
| Indicates whether the acc/inc occurred off or on an airport | Off Airport/Airstrip |
| Distance from airport in statute miles | -- |
| Degrees magnetic from airport | -- |
| Airport Elevation | -- |
| Weather Briefing Completeness | -- |
| Investigator's weather source | Weather Observation Facility |
| Time of the weather observation | 1956 Central Daylight Time |
| Direction of event from weather observation facility (degrees) | -- |
| Weather Observation Facility ID | ORD |
| Elevation of weather observation facility | 655 |
| Distance of event from weather observation facility (units?) | -- |
| Time Zone of the weather observation | CDT |
| Lighting Conditions | Night |
| Lowest Ceiling Height | 1700 |
| Lowest Non-Ceiling Height | -- |
| Sky/Lowest/Cloud Conditions | Clear |
| Sky Condition for Lowest Ceiling | Overcast |
| Visibility Runway Visual Range (Feet) | -- |
| Visibility Runway Visual Value (Statute Miles) | -- |
| Visibility (Statute Miles) | 10 |
| Air Temperature at event time (in degrees celsius) | 11 |
| Dew Point at event time (in degress fahrenheit) | 8 |
| Wind Direction (degrees magnetic) | 10 |
| Variable Wind Indicator | Wind direction could be determined |
| Wind Speed (knots) | -- |
| Wind Velocity Indicator | -- |
| Wind Gust Indicator | Unknown |
| Wind Gust (knots) | -- |
| Altimeter Setting at event time (in. Hg) | 30.12 |
| Density Altitude (feet) | -- |
| Intensity of Precipitation | -- |
| METAR weather report | -- |
| Event Highest Injury | None |
| On Ground, Fatal Injuries | -- |
| On Ground, Minor Injuries | -- |
| On Ground, Serious Injuries | -- |
| Injury Total Fatal | -- |
| Injury Total Minor | -- |
| Injury Total None | 5 |
| Injury Total Serious | -- |
| Injury Total All | -- |
| Investigating Agency | NTSB |
| NTSB Docket Number (internal use) | 22316 |
| NTSB Notification Source | FAA |
| NTSB Notification Date | Oct 20 2004 12:00AM |
| NTSB Notification Time | 2230 |
| Fiche Number and/or location -used to find docket information | DMS |
| Date of most recent change to record | Nov 29 2007 8:02AM |
| User who most recently changed record | NTSB\johb |
| Basic weather conditions | Visual Meteorological Cond |
| FAA District Office | Detroit FSDO |
Aircraft Involved |
|
|---|---|
Aircraft #1 |
|
| Aircraft Registration Number | N709CK |
| NTSB Number | CHI05MA011 |
| Missing Aircraft Indicator | -- |
| Federal Aviation Reg. Part | Part 121: Air Carrier |
| Type of Flight Plan filed | IFR |
| Flight plan Was Activated? | No |
| Damage | Substantial |
| Aircraft Fire | None |
| Aircraft Explosion | None |
| Aircraft Manufacturer's Full Name | Boeing |
| Aircraft Model | 747-132 |
| Aircraft Series Identifier | -- |
| Aircraft Serial Number | 20247 |
| Certified Max Gross Weight | -- |
| Aircraft Category | Airplane |
| Aircraft Registration Class | -- |
| Aircraft is a homebuilt? | No |
| Flight Crew Seats | -- |
| Cabin Crew Seats | -- |
| Passenger Seats | -- |
| Total number of seats on the aircraft | 7 |
| Number of Engines | 4 |
| Fixed gear or retractable gear | Retractable |
| Aircraft, Type of Last Inspection | Continuous Airworthiness |
| Date of Last Inspection | Oct 1 2004 12:00AM |
| Airframe hours since last inspection | 94.1 |
| Airframe Hours | 93548.7 |
| ELT Installed | -- |
| ELT Activated | -- |
| ELT Aided Location of Event Site | -- |
| ELT Type | -- |
| Aircraft Owner Name | Kalitta Air, LLC |
| Aircraft Owner Street Address | 818 Willow Run Airport |
| Aircraft Owner City | Ypsilanti |
| Aircraft Owner State | MI |
| Aircraft Owner Country | USA |
| Aircraft Owner Zipcode | 48198 |
| Operator is an individual? | No |
| Operator Name | -- |
| Operator Same as Owner? | Yes |
| Operator Is Doing Business As | -- |
| Operator Address Same as Owner? | Yes |
| Operator Street Address | -- |
| Operator City | -- |
| Operator State | -- |
| Operator Country | -- |
| Operator Zip code | -- |
| Operator Code | KCSA |
| Owner has at least one certificate | -- |
| Other Operator of large aircraft? | -- |
| Certified for Part 133 or 137 Operation | -- |
| Operator Certificate Number | -- |
| Indicates whether an air carrier operation was scheduled or not | Non-scheduled |
| Indicates Domestic or International Flight | International |
| Operator carrying Pax/Cargo/Mail | Cargo |
| Type of Flying (Per_Bus / Primary) | -- |
| Second Pilot on Board | Yes |
| Departure Point Same as Event | No |
| Departure Airport Code | ORD |
| Departure City | CHICAGO |
| Departure State | IL |
| Departure Country | USA |
| Departure Time | 2010 |
| Departure Time Zone | CDT |
| Destination Same as Local Flt | -- |
| Destination Airport Code | JFK |
| Destination City | NEW YORK |
| Destination State | NY |
| Destination Country | USA |
| Specific Phase of Flight | Climb |
| Report sent to ICAO? | No |
| Evacuation occurred | No |
| Date of most recent change to record | Sep 4 2007 2:04PM |
| User who most recently changed record | DINC |
| Since inspection or accident | -- |
| Event Location Runway Number and Location | NA |
| Runway Length | -- |
| Runway Width | -- |
| Sight Seeing flight | No |
| Air Medical Flight | No |
| Medical Flight | -- |