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[narrator] With over 100,000flights departing each day
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from airports around the world,
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the aviation industryhas cemented itself
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into our daily lives.
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[Rob] Aviation is often quoted
as the safest form of transport,
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but whenever there is
an accident, sadly,
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they're often examples
of fatal engineering.
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Japan, 1985.
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520 people died when JapanAirlines Flight 123 encountered
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a terrifying and unprecedentedtechnical problem.
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It's a single blow that causes
a chain reaction of disaster.
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Four years later,England, 1989.
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An engine failureand insufficient pilot training
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resulted in the deathof 47 passengers.
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If you're gonna shut down
an engine, you need to make
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sure that you're shutting
down the right one.
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In the summerof 1996, off the coast
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of New York, TWA Flight 800explodes 12 minutes
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after takeoff due toa terrifying and unprecedented
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chemical phenomenon aboarda commercial airliner.
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All it would take was a spark
to turn the central wing tank
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into a bomb.
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Were these accidents the resultof unavoidable circumstances?
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Or were they examplesof fatal engineering?
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[electronic theme music playing]
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Wednesday, July 17, 1996.It's 8:19 pm.
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[suspenseful music playing]
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TWA's flight 800 takes offfrom New York, bound for Paris,
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with 230 passengersand crew on board.
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-[suspenseful music playing]
-[engine roaring]
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[pilot over radio]
TWA's lifeguard 800 heavy,
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eight thousand, two hundred
climbing on one thousand.
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This aircraft has beenin service for 25 years,
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logging over 93,000flight hours.
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[Rob]
You could call it a real veteran
with an impressive track record,
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but on this particular day,
none of those passengers
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will reach
their final destination.
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[suspenseful music intensifies]
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Just 12 minutes later,
disaster would strike.
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As air traffic control attempts
to reach out to flight 800,
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they receive only silence.
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As the TWA Boeing climbsto its cruising altitude,
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people onthe ground and an airline pilot
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aboard a nearby aircraft
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see the plane explode inmidair over the Atlantic Ocean,
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some 15 kilometersfrom Long Island.
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[explosion blasting]
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[Tower] Eastwind 507,
you reported an explosion.
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Is that correct, sir?
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[pilot] Yes, sir,
about five miles out.
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[Tower] TWA 800 -- [indistinct].
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-[pilot] I think that was him.
-[Tower] I think so.
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What happened?
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What caused the deathsof the 230 people on board?
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[Shini] Though many on the
ground have suspected terrorism,
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claiming to have seen missiles
directed up towards Flight 800.
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The reality is perhaps
far more terrifying.
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Right now, the Coast Guard,
the National Transportation
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Safety Board, the FAA,
and the FBI are on the scene
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of the crash.
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Using massive search equipment,they located the wreck
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at a depth of 37 meters.
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In the wreckage,they retrieved the cockpit
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voice and flight datarecorders.
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[indistinct speaking
over radio]
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These two orange boxes arethe final moments of TWA 800.
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They offer to the investigatorsa valuable first clue
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and point themin a surprising direction.
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[Michel speaking French]
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It's a strange occurrence
that might provide a key clue.
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The malfunctioning fuel quality
indicators might be
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the smoking gun.
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Additionally, the cockpitrecorder reveals two unusual
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aircraft sounds, soundsthat pilots and mechanics
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can't interpret.
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It's 8:31 p.m., the time whenthe flight recordings stop,
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the moment the plane explodes.
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Eventually, the experts manageto bring to the surface almost
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500,000 pieces of wreckage,
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95% of the aircraft,
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and reconstructed itin this Long Island hangar.
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It is here that they will cometo understand the drama
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that has played outin this aircraft.
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[speaking French]
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And what they discovered
was that the explosion
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that occurred could not have
come from an external object.
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This explosion started
on the inside and blew out.
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[Shini] The fuselage of the
aircraft had been bent outwards
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around the wing center section
of the aircraft.
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The center sectionof the aircraft is the area
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between the wings.
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This is one ofthe strongest sections,
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with the fuselage connectedto the wings through structural
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elements like spanwisebeams and spars.
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This section also housesa critical component involved
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in the accident.
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In a large aircraft,
like the Boeing 747,
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you need a huge amount of fuel
to fly the massive distances
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that they do.
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And the majority of that fuel
is stored within the wings
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and within what's called
a central fuel tank, which sits
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in between the wings
within the fuselage itself.
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This is the largest of all
fuel tanks on the 747.
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The central wing tank can carryalmost 50,000 liters of fuel.
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But on this particular day,it's almost empty.
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[speaking in French]
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That central fuel tank didn't
need to be full.
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There was enough fuel in other
fuel tanks around the aircraft.
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The central fuel tank on this
flight only had about 2%
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of its maximum capacity.
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It contains only 300 gallonskerosene.
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Kerosene is partly chosen due
to the fact that as a fuel,
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if you took a match to it
and tried to light it as
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a liquid, it's just
gonna put the match out.
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It's not that volatile
as a liquid, but as a vapor,
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it becomes much more volatile.
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All that was needed to create
it was a heat source and time.
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And that heat is not far away.
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Beneath the central wing tanklie elements responsible
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for the drama to come.
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[speaking in French]
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In summer, temperaturesin New York can exceed
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30 degrees Celsius.
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On July 17, 1996, TWA Flight800 was originally scheduled
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to take off at 7 p.m.
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However, it wasdelayed at the gate,
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with its passengers alreadyon board.
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A fleet service vehicle,
which helps to load and unload
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aircraft between flights,
has broken down,
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blocking the aircraft
at the gate.
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Meaning that it wouldn't be
able to pull back
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to go out to the runways
and take off.
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Secondly, there was some
confusion around
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passengers' luggage.
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As a result,the plane remains grounded.
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But throughout the waitfor takeoff, the cabin remains
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air conditioned for the comfortof the passengers.
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[Shini] What seems like a fairly
routine, though frustrating,
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inconvenience has created
a deadly situation
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in the plane's center wing tank.
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Soon, it will develop
into a fatal disaster.
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July 17, 1996.
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TWA Flight 800 wasoriginally scheduled
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to take off at 7 p.m.
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However, it wasdelayed at the gate,
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with its passengers alreadyon board.
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Nobody knows it, but twoof the three air conditioning
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motors are heating upthe 1,000 liters of kerosene
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in the center wing tank.
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This action createsan unprecedented situation,
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terribly dangerousfor the entire aircraft
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and its passengers.
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That central fuel tank,
with a small amount of fuel
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in it, is getting warmer
and warmer and warmer.
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Though the aircraft's center
wing fuel tank was only loaded
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with 300 gallons of fuel
for the flight to Paris,
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there was another substance
slowly building up inside it
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that would prove fatal.
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This substance is known as fuelvapor, and in a kerosene tank,
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it's an extremelydangerous gas.
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[Michel speaking French]
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[Shini] All it would take
was a spark
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to turn the central wing tank
into a bomb.
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8:02 p.m.
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TWA 800 is finally clearedto leave its gate.
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It receives its departureclearance and joins the queue
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of aircraft awaiting takeoff.
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Between its arrivaland departure, the aircraft has
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been on the groundfor two hours and 45 minutes,
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with two of its three airconditioning motors operating
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at maximum capacity.
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8:19 p.m., the pilot setsthe engines to full power
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to take off fromthe end of the runway.
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[tower] TWA 800...
Climb and maintain one-three
thousand.
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[captain] TWA's 800 heavy climb
and maintain one-three
thousand..
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This is when a sparkis introduced.
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The flight recordings showthat 10 minutes after takeoff,
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at precisely 8:29 p.m.,the captain of TWA 800
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commented on the abnormalmovements of the fuel gauges.
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He is then cut off when airtraffic control asked him
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him to climb to 15,000 feet.
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Unfortunately, he never reachesthis altitude.
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The jittery gauges in frontof the captain reflect what's
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going on in the central tank.
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The hot, dense fuel vapordisturbs the seven
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probes inside.
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[Michel speaking French]
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These electric components
operate safely within close
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proximity to volatile
substances like jet fuel.
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Even if there was a spark,
it wouldn't have enough energy
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to ignite a combustion of fuel.
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But that wiring was also
bundled with other cabling
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00:11:47,166 --> 00:11:49,867
and other wiring systems
within the aircraft.
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And those wires had larger
currents running through them.
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This grouping of cables providethe final element to complete
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this explosive cocktail.
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00:12:00,467 --> 00:12:02,734
What's believed to have
happened was that those little
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crackles that were heard by
the captain and the flight crew
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up in the cockpit...
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with a short circuit and
some of those cabling systems
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that required a larger current,
there's your spark,
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the third element needed
for combustion.
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Fuel,
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oxygen, spark.
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The rest is inevitable.
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The time is 8:31 p.m.
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As the plane reachesan altitude of 13,800 feet,
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the fatal cocktail explodes.
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00:12:44,300 --> 00:12:49,000
A massive explosion takes place
within the central wing tank...
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00:12:51,467 --> 00:12:56,066
blowing out that central part
of the aircraft, a key part
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for its structural integrity.
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00:13:00,200 --> 00:13:04,500
The plane starts to buckle,
and the front of the aircraft
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00:13:04,667 --> 00:13:07,200
tears itself away from the back.
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00:13:07,367 --> 00:13:10,500
The cockpit, with a few rows
of seats behind,
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00:13:10,667 --> 00:13:13,066
plummets down into the ocean.
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00:13:13,233 --> 00:13:16,567
[Shini]
The rest of the plane continued
in the air, the wings still
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00:13:16,734 --> 00:13:19,867
connected to what remained
of the aircraft's fuselage.
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00:13:19,867 --> 00:13:21,467
[speaking French]
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00:13:41,767 --> 00:13:45,567
It took four yearsand $35 million to complete one
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00:13:45,567 --> 00:13:48,667
of the largest airinvestigations in history.
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00:13:50,867 --> 00:13:53,100
Following the accident,
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modifications were made tothe aircraft's internal wiring
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00:13:57,233 --> 00:13:59,900
to prevent such a scenariofrom happening again.
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00:14:01,567 --> 00:14:04,900
[Rob] Firstly, the wiring was
reconfigured so that no longer
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00:14:05,066 --> 00:14:08,166
would you have those
low current wires bundled
226
00:14:08,333 --> 00:14:09,867
with higher current.
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00:14:09,867 --> 00:14:12,567
The chance of a spark
and an energy being transferred
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00:14:12,567 --> 00:14:15,367
into the fuel tanks
was eliminated.
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00:14:15,367 --> 00:14:18,300
Secondly, regulations were
introduced to make sure
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00:14:18,467 --> 00:14:21,367
that never again would you be
allowed to take off
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00:14:21,533 --> 00:14:25,266
with a small amount of fuel that
could easily turn into a vapor.
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00:14:25,433 --> 00:14:28,100
And finally, increased
insulation was installed
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00:14:28,100 --> 00:14:31,567
between the air conditioning
units and the central
fuel tank.
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00:14:32,667 --> 00:14:35,867
The flight of TWA 800turned into one
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00:14:36,033 --> 00:14:38,567
of the world's greatestair disasters.
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00:14:40,567 --> 00:14:43,367
But what happens when
you combine new aircraft
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00:14:43,533 --> 00:14:48,400
engineering design with old
ways of thinking, human error
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00:14:48,567 --> 00:14:51,300
can often also be the cause
of fatal engineering.
239
00:15:07,433 --> 00:15:11,533
On January the 8th, 1989,
British Midlands flight 92
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00:15:11,700 --> 00:15:15,467
takes off from London Heathrow
on its way to Belfast
241
00:15:15,634 --> 00:15:17,433
in Northern Ireland,
242
00:15:17,600 --> 00:15:19,867
a flight it would have done
many times before.
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00:15:19,867 --> 00:15:23,066
[Shini]
This flight would be flown
by a brand new aircraft and had
244
00:15:23,233 --> 00:15:26,333
been delivered to British
Midlands Airways one month
245
00:15:26,500 --> 00:15:31,166
prior to that date,
Boeing's brand-new 737-400.
246
00:15:31,333 --> 00:15:34,467
Major changes from previousversions of the 737
247
00:15:34,634 --> 00:15:37,133
include its modern dashboardwith the introduction
248
00:15:37,300 --> 00:15:39,567
of digital functionsand its revolutionary
249
00:15:39,734 --> 00:15:42,567
new CFM56 engines.
250
00:15:43,467 --> 00:15:47,767
When the 126 passengersand crew board Flight 92,
251
00:15:47,934 --> 00:15:51,367
they have no doubt about thereliability of this aircraft.
252
00:15:51,533 --> 00:15:55,066
However, they will neverreach their destination.
253
00:15:57,533 --> 00:16:00,867
27 minutes after takeoff,this masterpiece
254
00:16:00,867 --> 00:16:03,467
of aeronautical engineeringloses the use
255
00:16:03,634 --> 00:16:04,934
of one of its engines.
256
00:16:06,867 --> 00:16:11,166
Diverted for an emergencylanding, it crashed 900 meters
257
00:16:11,166 --> 00:16:13,233
from the runwayat East Midlands Airport,
258
00:16:13,400 --> 00:16:16,433
South of Nottingham,in the small town of Kegworth.
259
00:16:19,867 --> 00:16:22,834
[sirens wailing]
260
00:16:28,734 --> 00:16:31,433
Despite the violenceof the impact that kills
261
00:16:31,600 --> 00:16:35,734
47 people, 74 passengersand crew miraculously survived
262
00:16:35,900 --> 00:16:38,100
this terrible crash.
263
00:16:38,266 --> 00:16:40,934
I was suspended upside down,
just with my safety belt
264
00:16:41,100 --> 00:16:44,567
holding me on and my wife
just down below me.
265
00:16:44,734 --> 00:16:47,333
The captain isamong the survivors.
266
00:16:47,500 --> 00:16:50,467
Injured in his back and legs,he is hailed for his courage
267
00:16:50,634 --> 00:16:51,867
and decision making.
268
00:16:51,867 --> 00:16:53,734
[speaking French]
269
00:16:59,166 --> 00:17:01,867
To understand this,we need to go back 30 minutes
270
00:17:02,033 --> 00:17:03,233
before the crash.
271
00:17:05,266 --> 00:17:06,634
8:52 p.m.
272
00:17:06,800 --> 00:17:09,834
British Midland Flight 92departs from Heathrow Airport
273
00:17:10,000 --> 00:17:11,100
in London.
274
00:17:11,100 --> 00:17:14,934
13 minutes after takeoff,precisely at 9:05 p.m.,
275
00:17:15,100 --> 00:17:18,734
as the plane nears its cruisingaltitude, a worrying phenomenon
276
00:17:18,900 --> 00:17:20,066
occurs on board.
277
00:17:20,066 --> 00:17:22,867
[Rob] The pilots and a number
of the passengers realize
278
00:17:23,033 --> 00:17:24,567
that something's not
quite right.
279
00:17:24,734 --> 00:17:28,967
There's some vibrations
that feel more than what you'd
280
00:17:29,133 --> 00:17:32,667
normally expect, and you can
feel it in the aircraft.
281
00:17:32,834 --> 00:17:35,467
What they don't know isthat there's a problem in one
282
00:17:35,467 --> 00:17:37,567
of the two engines.
283
00:17:37,567 --> 00:17:41,734
The CFM56 is made up of twoinseparable elements that will
284
00:17:41,900 --> 00:17:44,834
be the key componentsin this deadly accident.
285
00:17:45,000 --> 00:17:47,467
[speaking French]
286
00:18:09,834 --> 00:18:12,834
The essential componentfor making an aircraft fly
287
00:18:13,000 --> 00:18:14,133
is the fan.
288
00:18:14,133 --> 00:18:17,567
It is made up of 38 blades,each 1.5 meters long.
289
00:18:17,567 --> 00:18:22,000
These blades turn and they draw
in a huge amount of air
290
00:18:22,166 --> 00:18:26,233
and thrust it out the back
that propels the engine forward.
291
00:18:27,634 --> 00:18:31,066
But as the investigation willreveal, one of the blades will
292
00:18:31,233 --> 00:18:32,734
be the source of the problem.
293
00:18:34,634 --> 00:18:39,567
Blade number 17 has suffered
a crack and it's shifted
294
00:18:39,567 --> 00:18:42,734
its position slightly
within the configuration.
295
00:18:42,900 --> 00:18:45,266
Not only does Blade 17 crack,
296
00:18:45,433 --> 00:18:49,266
but as the engine continuesto rotate, it begins to twist.
297
00:18:49,266 --> 00:18:52,567
As a result, the gap betweenthis blade and the one adjacent
298
00:18:52,567 --> 00:18:55,834
to it widens, allowing more airto pass at that point
299
00:18:56,000 --> 00:18:57,133
through the engine.
300
00:18:57,133 --> 00:19:00,066
As the fan continues to rotateat a speed of 20,000
301
00:19:00,066 --> 00:19:02,834
revolutions per minute,this excess airflow
302
00:19:03,000 --> 00:19:05,967
destabilizes the fanand threatens the proper
303
00:19:06,133 --> 00:19:07,233
functioning of the engine.
304
00:19:09,667 --> 00:19:12,166
[speaking French]
305
00:19:32,367 --> 00:19:36,533
That blade, having shifted
just a few millimeters, is now
306
00:19:36,700 --> 00:19:39,767
touching the outer casing
of the cowling
307
00:19:39,934 --> 00:19:41,567
that contains the engine.
308
00:19:42,667 --> 00:19:46,000
As passengers look throughthe windows, they see sparks
309
00:19:46,166 --> 00:19:47,467
coming from the left engine.
310
00:19:47,467 --> 00:19:51,233
Then they experience a secondterrifying event,
311
00:19:51,400 --> 00:19:52,834
smoke in the cabin.
312
00:19:53,000 --> 00:19:55,667
[speaking French]
313
00:20:11,166 --> 00:20:13,233
At this point,everyone understands
314
00:20:13,400 --> 00:20:15,634
that the situation is abnormal,and there is
315
00:20:15,800 --> 00:20:17,233
a problem with the aircraft.
316
00:20:18,533 --> 00:20:21,533
The passengers begin to panic.
317
00:20:21,700 --> 00:20:24,967
The captain and his copilotare highly experienced.
318
00:20:25,133 --> 00:20:28,367
They have over 16,000flight hours between them,
319
00:20:28,533 --> 00:20:32,166
including 1,000 hourson the Boeing 737.
320
00:20:32,333 --> 00:20:35,166
Critically, however,only 76 of those hours
321
00:20:35,166 --> 00:20:37,867
are on this new modelof the 737.
322
00:20:38,033 --> 00:20:41,467
Only one day of training wasrequired by the manufacturer
323
00:20:41,467 --> 00:20:45,667
to obtain their certificationto fly the Boeing 737-400.
324
00:20:45,667 --> 00:20:48,367
This included all the newfeatures of the aircraft,
325
00:20:48,533 --> 00:20:50,567
as well as the nuancesof the aircraft
326
00:20:50,567 --> 00:20:52,533
in emergency situations.
327
00:20:53,667 --> 00:20:57,967
Relatively new to the Boeing
737-400, they're about to make
328
00:20:58,133 --> 00:21:01,333
several fatal assumptions
and miscalculations.
329
00:21:01,500 --> 00:21:03,967
The two pilots understand thatthere is an issue with
330
00:21:04,133 --> 00:21:07,000
one of the engines and beginto assess the situation.
331
00:21:09,467 --> 00:21:12,967
They decide to shut down
the engine that's causing
332
00:21:13,133 --> 00:21:14,567
these vibrations.
333
00:21:14,734 --> 00:21:16,734
Now, that in itself
isn't a big deal.
334
00:21:16,900 --> 00:21:18,266
It happens fairly regularly.
335
00:21:18,266 --> 00:21:19,533
When something's wrong
with an engine,
336
00:21:19,700 --> 00:21:20,834
you can shut
it down.
337
00:21:20,834 --> 00:21:24,567
The aircraft, like the Boeing
737-400, can fly safely
338
00:21:24,734 --> 00:21:26,467
on one engine.
339
00:21:26,634 --> 00:21:28,734
But if you're gonna shut
down an engine, you need
340
00:21:28,900 --> 00:21:31,567
to make sure that you're
shutting down the right one.
341
00:21:35,867 --> 00:21:37,433
British Midland Flight 92
342
00:21:37,600 --> 00:21:39,533
departs fromHeathrow Airport in London.
343
00:21:40,266 --> 00:21:42,767
The pilots can clearly seeon their instruments
344
00:21:42,767 --> 00:21:44,333
that something is wrong.
345
00:21:45,767 --> 00:21:49,233
However, they are not used tothe brand-new digital screens
346
00:21:49,400 --> 00:21:50,967
on the dashboard.
347
00:21:51,133 --> 00:21:52,266
The pilots can clearly see
348
00:21:52,266 --> 00:21:54,967
that something's wrong
with the left-hand engine.
349
00:21:55,133 --> 00:21:56,967
Their instrumentation
is showing it.
350
00:21:58,066 --> 00:22:01,133
They can also
feel the vibrations.
351
00:22:01,300 --> 00:22:04,433
However, as strange as it mayseem, the pilots will make
352
00:22:04,600 --> 00:22:06,433
a mistake that willprove fatal.
353
00:22:06,600 --> 00:22:07,767
[engine whirring]
354
00:22:10,233 --> 00:22:13,033
[speaking French]
355
00:22:13,200 --> 00:22:14,667
The left-hand engine
that's causing
356
00:22:14,834 --> 00:22:17,266
vibrations is now
the only thing providing
357
00:22:17,433 --> 00:22:20,367
thrust, keeping the plane
in the sky.
358
00:22:20,367 --> 00:22:24,166
The flight continues flying
on a single failing engine.
359
00:22:24,333 --> 00:22:27,367
However, they do not yetrealize their mistake.
360
00:22:27,367 --> 00:22:30,533
When they shut down the workingengine, the cockpit gauges
361
00:22:30,700 --> 00:22:31,834
return to normal.
362
00:22:32,000 --> 00:22:34,066
The vibrationsand the smoke stop.
363
00:22:34,233 --> 00:22:36,467
[speaking French]
364
00:22:48,266 --> 00:22:52,533
[Rob] And so it feels to the
cockpit that everything is fine.
365
00:22:52,700 --> 00:22:55,333
The right decision has been
made, and we're going to land
366
00:22:55,500 --> 00:22:58,967
in East Midlands Airport off
of the power from one engine.
367
00:22:59,967 --> 00:23:03,066
At this point, they still havetime to realize their mistake
368
00:23:03,233 --> 00:23:05,634
and restart the engine,but they take no
369
00:23:05,800 --> 00:23:07,166
further action.
370
00:23:07,333 --> 00:23:10,533
The passengers can clearly see
that smoke,
371
00:23:10,700 --> 00:23:14,567
and flames and sparks are still
coming out from this engine.
372
00:23:16,367 --> 00:23:19,667
As flight 92 aligns
with the runway, the throttle is
373
00:23:19,667 --> 00:23:22,333
pushed forward,
increasing the power demanded
374
00:23:22,500 --> 00:23:23,734
from the left engine.
375
00:23:23,900 --> 00:23:25,667
That is the turning point.
376
00:23:30,333 --> 00:23:33,066
[speaking French]
377
00:23:47,867 --> 00:23:49,266
It is 9:18 p.m.
378
00:23:49,266 --> 00:23:52,133
The flames and vibrationsreappear.
379
00:23:53,467 --> 00:23:55,867
During the investigation,part of the outer casing
380
00:23:55,867 --> 00:24:00,066
of blade 17, as well asfragments from blades 4 and 5,
381
00:24:00,066 --> 00:24:02,634
were found during flight 92'sfinal approach
382
00:24:02,800 --> 00:24:04,266
to East Midlands Airport.
383
00:24:05,867 --> 00:24:09,133
Blade 17, which had already
suffered fatigue damage
384
00:24:09,300 --> 00:24:12,734
and came loose within
the engine's fan, had possibly
385
00:24:12,900 --> 00:24:16,033
been ingested by the engine,
released from a trapped
386
00:24:16,200 --> 00:24:19,166
position, damaging other
fan blades as it's drawn
387
00:24:19,166 --> 00:24:20,634
through the engine.
388
00:24:20,800 --> 00:24:22,567
[speaking French]
389
00:24:38,634 --> 00:24:43,834
It becomes clear they will not
make it to the runway.
390
00:24:44,000 --> 00:24:46,166
They're forced to make
the decision that no pilot ever
391
00:24:46,166 --> 00:24:49,767
wants to make.
Forced to make a crash landing.
392
00:24:51,667 --> 00:24:55,667
Between the plane and the
runway is one of the busiest
393
00:24:55,834 --> 00:24:58,967
motorways in the UK,
the M1, and the plane's heading
394
00:24:59,133 --> 00:25:00,100
straight for it.
395
00:25:00,100 --> 00:25:02,266
The pilots don't havemany options.
396
00:25:02,266 --> 00:25:04,867
In fact, they only havetwo choices.
397
00:25:04,867 --> 00:25:07,533
[speaking French]
398
00:25:38,767 --> 00:25:42,367
The pilot chooses to crash ontothe slope near the highway.
399
00:25:42,367 --> 00:25:45,867
30 minutes after taking offfrom London, the captain makes
400
00:25:45,867 --> 00:25:50,333
the most dreaded announcementa commercial pilot can make.
401
00:25:50,500 --> 00:25:54,867
Captain Hunt uses the intercom
to ask passengers to prepare
402
00:25:54,867 --> 00:25:56,100
for a crash landing.
403
00:26:00,066 --> 00:26:01,734
Some passengers manage
to get themselves
404
00:26:01,900 --> 00:26:05,567
into the brace position.
Others do not.
405
00:26:05,567 --> 00:26:08,767
Violent vibrations insidethe cabin cause the overhead
406
00:26:08,767 --> 00:26:11,033
compartments to open,and luggage falls
407
00:26:11,200 --> 00:26:13,967
onto the terrified passengers.
408
00:26:14,133 --> 00:26:17,266
The plane loses thrustand begins to dive.
409
00:26:19,567 --> 00:26:22,667
The plane makes contact
with the ground on one side
410
00:26:22,834 --> 00:26:27,266
of the motorway, crashing
through fields and some trees,
411
00:26:27,433 --> 00:26:29,233
crosses the motorway.
412
00:26:29,400 --> 00:26:32,233
[Shini] The forward section
splits and continues onwards
413
00:26:32,400 --> 00:26:35,533
up the embankment, while
the tail of the plane separates
414
00:26:35,700 --> 00:26:37,834
and folds up on top
of the midsection
415
00:26:38,000 --> 00:26:41,100
and the passengers in the main
cabin section of the aircraft.
416
00:26:46,066 --> 00:26:49,567
British Midland Flight 92crashes just 900 meters
417
00:26:49,567 --> 00:26:52,934
from the runwayof East Midlands Airport.
418
00:26:53,100 --> 00:26:56,266
Miraculously, no oneon the highway is injured.
419
00:26:56,266 --> 00:26:59,634
You might argue that this was
a case of fatal engineering
420
00:26:59,800 --> 00:27:02,433
because of the errors
that occurred in that left-hand
421
00:27:02,600 --> 00:27:04,767
side engine, the cracks,
the movement
422
00:27:04,934 --> 00:27:06,767
of the turbine blades
that caused the fire
423
00:27:06,934 --> 00:27:08,100
and the vibrations.
424
00:27:08,266 --> 00:27:11,767
But in this case, the pilot made
the wrong decision.
425
00:27:11,767 --> 00:27:13,567
[speaking French]
426
00:27:31,233 --> 00:27:35,433
Because of this fatal error,47 people died, and 74
427
00:27:35,600 --> 00:27:39,433
will carry the lasting effectsof their severe injuries.
428
00:27:39,600 --> 00:27:42,567
This avoidable tragedy causeda shockwave throughout
429
00:27:42,567 --> 00:27:44,166
the aviation industry.
430
00:27:44,333 --> 00:27:47,467
Due to Captain Hunt
and First Officer McClelland's
431
00:27:47,634 --> 00:27:51,133
relative inexperience
in the Boeing 737-400
432
00:27:51,300 --> 00:27:54,867
under such dire
circumstances and Boeing's
433
00:27:55,033 --> 00:27:58,166
inadequate pilot training,
recommendations were made
434
00:27:58,333 --> 00:28:01,467
to ensure all pilots
are thoroughly prepared
435
00:28:01,634 --> 00:28:05,867
before taking control
of a new aircraft variation.
436
00:28:06,033 --> 00:28:08,367
[Rob] Undoubtedly, the catalyst
for the British Midlands
437
00:28:08,367 --> 00:28:12,333
aircraft disaster was a fault
within the engine.
438
00:28:12,500 --> 00:28:15,667
But what happens when
your engines are working fine,
439
00:28:15,834 --> 00:28:19,333
but you lose the ability
to control the plane in the air?
440
00:28:23,867 --> 00:28:26,667
We're in Japanat Tokyo's Haneda Airport
441
00:28:26,667 --> 00:28:28,867
on August 12, 1985.
442
00:28:28,867 --> 00:28:32,634
Japan Airlines flight 123departs for Osaka.
443
00:28:32,800 --> 00:28:34,066
It's 6:12 p.m.
444
00:28:35,367 --> 00:28:39,867
This is a 54 minute flight,
so a relatively short flight.
445
00:28:39,867 --> 00:28:42,166
But in Japan, the number
of people wanting to make
446
00:28:42,166 --> 00:28:44,100
this flight is huge.
447
00:28:44,266 --> 00:28:49,734
And so Japan Airlines regularly
use a Boeing 747, crammed full
448
00:28:49,900 --> 00:28:52,967
with 500 passengers,
shifting people
449
00:28:53,133 --> 00:28:55,934
between Tokyo and Osaka.
450
00:28:56,100 --> 00:28:58,734
Specifically designedfor the Japanese market,
451
00:28:58,900 --> 00:29:01,667
this Boeing 747-SR46
452
00:29:01,667 --> 00:29:04,467
is the largest airlinerof its time, it can accommodate
453
00:29:04,634 --> 00:29:06,934
up to 550 passengers.
454
00:29:07,100 --> 00:29:11,166
With 524 passengers and crewmembers aboard, it is nearly
455
00:29:11,166 --> 00:29:14,266
full when it takesoff from Tokyo Airport.
456
00:29:14,433 --> 00:29:17,767
[Rob] Twelve minutes
into this particular flight,
457
00:29:17,767 --> 00:29:22,000
something goes devastatingly
wrong with the aircraft,
458
00:29:22,166 --> 00:29:24,367
and it never makes
its destination in Osaka.
459
00:29:24,367 --> 00:29:26,767
An explosion occursat the rear of the plane,
460
00:29:26,934 --> 00:29:30,033
depressurizing the cabin,and destroying both the tail's
461
00:29:30,200 --> 00:29:33,133
rudder and hydraulic systems,making the aircraft
462
00:29:33,300 --> 00:29:36,367
uncontrollable, a nightmarefor every passenger.
463
00:29:37,634 --> 00:29:39,967
For over 30 minutes,
the pilots fight
464
00:29:40,133 --> 00:29:42,734
with the aircraft,
repeatedly informing ground
465
00:29:42,900 --> 00:29:44,934
crews that they have
lost control.
466
00:29:45,100 --> 00:29:47,967
-[pilot yelling over radio]
-[engine roaring]
467
00:29:48,133 --> 00:29:50,367
[alarms beeping]
468
00:29:50,367 --> 00:29:55,467
At 6:56 p.m., 44 minutes afterits takeoff, the plane crashes
469
00:29:55,467 --> 00:29:57,533
into the slopesof Mount Osutaka,
470
00:29:57,700 --> 00:29:59,367
100 kilometers from Tokyo.
471
00:29:59,367 --> 00:30:01,934
[suspenseful music playing]
472
00:30:03,767 --> 00:30:07,000
The crash resultsin 520 deaths.
473
00:30:07,166 --> 00:30:10,467
Never has an aviation disasterinvolving a single aircraft
474
00:30:10,634 --> 00:30:12,767
claimed so many victims.
475
00:30:12,767 --> 00:30:16,667
Incredibly, rescue teamsmanaged to find four survivors
476
00:30:16,834 --> 00:30:18,266
within the wreckageof the plane.
477
00:30:20,333 --> 00:30:23,367
[Shini] But was such a tragic
loss of life avoidable?
478
00:30:23,533 --> 00:30:25,333
Were warning signs missed?
479
00:30:25,500 --> 00:30:29,000
Was flight 123 a case
of fatal engineering?
480
00:30:34,367 --> 00:30:36,333
[Rob] In order to understand
what's happened here,
481
00:30:36,500 --> 00:30:39,033
we need to go back in time
seven years back.
482
00:30:39,200 --> 00:30:43,066
When, on one occasion,
when this plane was taking off,
483
00:30:43,233 --> 00:30:44,767
it suffered a tail strike.
484
00:30:45,667 --> 00:30:48,834
In aviation, a tail strikerefers to the moment when
485
00:30:49,000 --> 00:30:51,066
the tail of the aircrafttouches the ground
486
00:30:51,233 --> 00:30:53,100
during takeoff or landing.
487
00:30:53,266 --> 00:30:56,166
This is what happenedon June 2nd, 1978,
488
00:30:56,333 --> 00:30:58,266
at Osaka Airport.
489
00:30:58,266 --> 00:31:00,767
[speaking French]
490
00:31:15,433 --> 00:31:18,967
As an airplane climbs higher,it enters a zone where the air
491
00:31:19,133 --> 00:31:23,100
is thinner, colder, andunsuitable for the human body.
492
00:31:23,266 --> 00:31:25,266
To maintain a comfortableatmosphere for the people
493
00:31:25,433 --> 00:31:29,367
on board, the cabin is keptat normal pressure.
494
00:31:29,533 --> 00:31:32,133
It is pressurized with airtaken from the aircraft's
495
00:31:32,300 --> 00:31:34,066
engines and pumpedinto the cabin.
496
00:31:35,166 --> 00:31:37,867
This disc-shaped bulkheadis the essential shield
497
00:31:38,033 --> 00:31:40,867
that separates the pressurizedrear cabin from the tail
498
00:31:40,867 --> 00:31:43,567
of the aircraft,which is not pressurized.
499
00:31:44,567 --> 00:31:47,233
[Shini] Without this bulkhead,
pressure would be lost through
500
00:31:47,400 --> 00:31:50,734
the back of the aircraft
and would be unable to maintain
501
00:31:50,900 --> 00:31:54,767
a suitable atmosphere
at a plane's cruising altitude.
502
00:31:54,767 --> 00:31:57,967
This is why all repairsmust be done meticulously,
503
00:31:58,133 --> 00:32:00,133
but in this case, it was not.
504
00:32:01,000 --> 00:32:03,767
Once the repair was finished,inspectors discovered
505
00:32:03,934 --> 00:32:05,734
an alarming situation.
506
00:32:05,900 --> 00:32:08,166
There were significant gapsbetween parts of the new
507
00:32:08,166 --> 00:32:10,667
bulkhead that threatenedits proper functioning.
508
00:32:13,100 --> 00:32:16,533
To solve this major issue,engineers decided to install
509
00:32:16,700 --> 00:32:21,100
a junction to serve as a sealbetween the two parts involved.
510
00:32:21,266 --> 00:32:24,066
However, the junction plate wasdifficult to install due
511
00:32:24,233 --> 00:32:27,533
to the curvature of boththe plate and the bulkhead.
512
00:32:27,700 --> 00:32:31,100
Boeing engineers decided to cutthe plate to install it
513
00:32:31,266 --> 00:32:35,133
and used half as many rivets asneeded, a choice that would be
514
00:32:35,300 --> 00:32:38,567
fatal for Japan AirlinesFlight 123.
515
00:32:38,734 --> 00:32:42,266
[speaking French]
516
00:32:54,967 --> 00:32:58,333
And over a period of time,
those repairs started
517
00:32:58,500 --> 00:33:02,567
to suffer cracks and started
to become unstable.
518
00:33:02,567 --> 00:33:06,967
On this flight, that instability
became disastrous.
519
00:33:07,133 --> 00:33:08,834
It was a ticking time bomb.
520
00:33:12,166 --> 00:33:15,934
August 12, 1985.
521
00:33:16,100 --> 00:33:19,767
The Japan Airlines Boeing 747has been in flight
522
00:33:19,934 --> 00:33:21,767
for 12 minutesand is approaching
523
00:33:21,767 --> 00:33:24,634
its cruising altitudeof 24,000 feet.
524
00:33:26,467 --> 00:33:28,967
[Shini] As passengers and crew
settled into the flight,
525
00:33:29,133 --> 00:33:31,834
a loud boom thunders
through the plane.
526
00:33:32,000 --> 00:33:35,367
Over time, cracks in theweakened area of the bulkhead
527
00:33:35,367 --> 00:33:37,767
created an air gapthat disrupted the balance
528
00:33:37,934 --> 00:33:39,567
of the cabin's pressurization.
529
00:33:40,567 --> 00:33:43,867
The bulkhead could notwithstand this influx of air.
530
00:33:43,867 --> 00:33:46,433
Inevitably, it explodes.
531
00:33:48,533 --> 00:33:51,166
Suddenly, the cabin is
no longer pressurized.
532
00:33:51,166 --> 00:33:55,767
It is exposed to the atmosphere
and the air pressure
533
00:33:55,767 --> 00:33:59,166
at the altitude where the plane
found itself, which is much
534
00:33:59,166 --> 00:34:02,634
lower than what we find
when we're on earth.
535
00:34:02,800 --> 00:34:04,967
As such, there's not
as much oxygen.
536
00:34:05,133 --> 00:34:08,967
The oxygen masks dropfrom the overhead compartments.
537
00:34:09,133 --> 00:34:12,333
The captain realizes the cabinis undergoing rapid
538
00:34:12,500 --> 00:34:15,834
depressurization and that thepassengers' lives are at risk.
539
00:34:16,000 --> 00:34:21,233
[captain speaking Japanese
over radio]
540
00:34:21,400 --> 00:34:24,634
He descends to a lower altitudeso the air becomes breathable
541
00:34:24,800 --> 00:34:27,567
for those on board and requestsan emergency landing
542
00:34:27,734 --> 00:34:29,333
at Tokyo Airport.
543
00:34:29,500 --> 00:34:35,367
[captain speaking Japanese
on radio]
544
00:34:35,533 --> 00:34:37,066
[tower speaking Japaense]
545
00:34:37,867 --> 00:34:41,533
[Rob] The crew knows something
has happened, but they can't see
546
00:34:41,700 --> 00:34:42,867
the entirety of the plane.
547
00:34:42,867 --> 00:34:45,467
They don't know exactly
the extent of the damage that's
548
00:34:45,467 --> 00:34:48,734
been caused by this loud bang,
this explosion somewhere
549
00:34:48,900 --> 00:34:50,667
in the aft of the plane.
550
00:34:50,834 --> 00:34:52,100
[speaking French]
551
00:34:54,166 --> 00:34:56,867
This photo was taken duringthat hellish flight
552
00:34:57,033 --> 00:34:59,333
by a witness on the ground.
553
00:34:59,500 --> 00:35:02,767
It illustrates the horrifyingtragedy of Japan Airlines
554
00:35:02,934 --> 00:35:07,467
Flight 123, carrying524 passengers and crew.
555
00:35:08,667 --> 00:35:14,166
Unbelievably, the tail is
missing from this aircraft.
556
00:35:14,166 --> 00:35:17,266
The tail will be foundin Sagami Bay, 60 kilometers
557
00:35:17,433 --> 00:35:18,867
from Tokyo Airport.
558
00:35:21,133 --> 00:35:24,100
When the partition exploded,the air pressure inside
559
00:35:24,266 --> 00:35:27,133
the cabin rushed towardthe tail of the plane.
560
00:35:27,300 --> 00:35:30,533
This extremely violentdecompression is the trigger
561
00:35:30,700 --> 00:35:32,367
for the worst case scenario.
562
00:35:33,867 --> 00:35:37,033
[speaking French]
563
00:35:51,934 --> 00:35:56,367
[Rob]
Without those two controls,
as the pilot, you have very
564
00:35:56,533 --> 00:36:00,100
little input to dictate
the movement of the aircraft.
565
00:36:01,834 --> 00:36:03,266
6:28 p.m.
566
00:36:04,467 --> 00:36:07,166
Four minutes after thepartition rupture and the loss
567
00:36:07,333 --> 00:36:10,100
of cabin pressure,the captain informs air traffic
568
00:36:10,266 --> 00:36:13,367
control that the planeis uncontrollable.
569
00:36:13,367 --> 00:36:17,266
They are given permissionto land at nearby airports.
570
00:36:17,433 --> 00:36:19,634
[tower speaking Japanese
on radio]
571
00:36:21,467 --> 00:36:23,834
[captain responding in Japanese]
572
00:36:26,266 --> 00:36:29,166
However, the aircraft beginsto perform maneuvers
573
00:36:29,166 --> 00:36:32,066
that are, at once,dangerous and terrifying.
574
00:36:32,233 --> 00:36:34,967
The phenomenon is knownas phugoid motion.
575
00:36:35,133 --> 00:36:38,567
It occurs when the aircraftrepeatedly gains and loses
576
00:36:38,567 --> 00:36:40,667
altitude in several phases.
577
00:36:40,834 --> 00:36:43,367
The plane comes down through
gravity, builds up speed,
578
00:36:43,533 --> 00:36:46,233
the lift in the wings
increases, and the plane
579
00:36:46,400 --> 00:36:47,734
goes up again.
580
00:36:47,900 --> 00:36:50,467
As it goes up, it loses
its speed, and so gravity
581
00:36:50,634 --> 00:36:52,266
dictates that it comes down,
almost like it's
582
00:36:52,266 --> 00:36:54,000
on a roller coaster.
583
00:36:55,934 --> 00:36:57,266
6:48 p.m.
584
00:36:58,467 --> 00:37:03,166
JAL flight 123 is now only7,000 feet above the mountain
585
00:37:03,166 --> 00:37:05,667
ranges of the Japanese Alps.
586
00:37:05,667 --> 00:37:07,767
The mountains are gettingcloser, and the crew
587
00:37:07,767 --> 00:37:10,834
desperately tries to find a wayto control the plane,
588
00:37:11,000 --> 00:37:14,066
as the flight controls areno longer responding.
589
00:37:15,033 --> 00:37:17,467
When the bulkhead rupturedand the pressure exploded
590
00:37:17,467 --> 00:37:21,100
in the tail of the aircraft,it wasn't just the vertical
591
00:37:21,266 --> 00:37:24,133
stabilizer and rudderthat were destroyed.
592
00:37:24,300 --> 00:37:27,233
The tail also containscomponents of another critical
593
00:37:27,400 --> 00:37:30,634
system onboard the aircraft,the hydraulic system.
594
00:37:30,800 --> 00:37:34,066
[Shini] The Boeing 747,
like most planes, uses a series
595
00:37:34,233 --> 00:37:38,767
of hydraulics to power flaps
on both the tail and the wings
596
00:37:38,767 --> 00:37:39,967
of the plane.
597
00:37:40,133 --> 00:37:42,934
By tilting these flaps
with ailerons, the pilot can
598
00:37:43,100 --> 00:37:45,567
then control airflow
around the plane,
599
00:37:45,734 --> 00:37:49,066
and therefore the plane's
direction and speed.
600
00:37:49,233 --> 00:37:52,367
However, when the explosionof the pressurization bulkhead
601
00:37:52,533 --> 00:37:56,100
tore off part of the tail,it also damaged hydraulic
602
00:37:56,266 --> 00:37:58,367
system pipes located there.
603
00:37:58,533 --> 00:38:00,867
The fluid they contained,vital for the system
604
00:38:00,867 --> 00:38:04,133
to function, graduallybegan to leak out.
605
00:38:04,300 --> 00:38:06,834
Within 60 to 90 secondsfollowing the explosion
606
00:38:07,000 --> 00:38:10,266
at the rear of the aircraft,hydraulic pressure was
607
00:38:10,266 --> 00:38:11,667
completely lost.
608
00:38:13,467 --> 00:38:15,266
6:50 p.m.
609
00:38:15,266 --> 00:38:20,033
The crew of JAL flight 123 haslost control of the aircraft
610
00:38:20,200 --> 00:38:21,367
for 26 minutes.
611
00:38:22,467 --> 00:38:24,634
[speaking French]
612
00:38:32,767 --> 00:38:34,867
[Rob] No matter how hard
he tries,
613
00:38:34,867 --> 00:38:36,767
his efforts
will be unsuccessful.
614
00:38:36,934 --> 00:38:39,667
For 30 minutes,the pilots fight courageously
615
00:38:39,834 --> 00:38:43,934
to keep this 260-ton aircraftin the air, a 30-minute
616
00:38:44,100 --> 00:38:47,433
nightmare for everyone onboard, during which passengers
617
00:38:47,600 --> 00:38:49,667
record their final moments.
618
00:38:49,834 --> 00:38:52,634
[speaking French]
619
00:38:59,767 --> 00:39:01,133
6:55 p.m.
620
00:39:01,300 --> 00:39:04,433
43 minutes after takeoff,the airports of Haneda
621
00:39:04,600 --> 00:39:06,867
and Yokota confirmthey are ready to receive
622
00:39:06,867 --> 00:39:09,767
flight 123for an emergency landing.
623
00:39:09,934 --> 00:39:12,967
[captain speaking Japanese
over radio]
624
00:39:18,000 --> 00:39:20,367
The crew on boardconfirms the message,
625
00:39:20,533 --> 00:39:22,667
but it's their lasttransmission.
626
00:39:24,233 --> 00:39:27,367
Despite the heroic efforts
of the pilot, inevitably
627
00:39:27,367 --> 00:39:28,867
the plane crashes.
628
00:39:29,033 --> 00:39:32,934
-[pilot yelling]
-[engine roaring]
629
00:39:33,100 --> 00:39:36,567
-[alarm beeping]
-[yelling continues]
630
00:39:44,100 --> 00:39:46,767
And it crashes
into a mountain ridge.
631
00:39:46,934 --> 00:39:49,634
[Shini] The plane continued
forward with the passengers
632
00:39:49,800 --> 00:39:54,367
in this section experiencing
forces greater than 10 to 20 G.
633
00:39:54,533 --> 00:39:56,767
[explosion rumbles]
634
00:40:05,734 --> 00:40:09,967
According to onboard seismicsensors, it is 6:56 p.m.
635
00:40:10,133 --> 00:40:11,567
when the plane the plane makesits final movements
636
00:40:11,734 --> 00:40:14,166
on the ground,and the debris settles
637
00:40:14,166 --> 00:40:15,400
into its final position.
638
00:40:17,867 --> 00:40:20,567
What we know is that there were
no survivors in the front
639
00:40:20,567 --> 00:40:24,233
of the aircraft, but there were
dozens of survivors
640
00:40:24,400 --> 00:40:25,500
in the rear.
641
00:40:25,500 --> 00:40:28,667
Despite the powerof the impact, some passengers
642
00:40:28,834 --> 00:40:30,000
have survived.
643
00:40:30,166 --> 00:40:31,867
However, they are ina remote area
644
00:40:32,033 --> 00:40:33,734
in the Osutaka Mountain Range,
645
00:40:33,900 --> 00:40:37,767
over 1,600 metersabove sea level in the middle
646
00:40:37,934 --> 00:40:39,100
of the night.
647
00:40:39,100 --> 00:40:41,867
They have to wait 12 hoursbefore rescue teams reach
648
00:40:42,033 --> 00:40:45,066
the crash site,12 hours that will be fatal
649
00:40:45,233 --> 00:40:47,166
for the majorityof the survivors.
650
00:40:49,634 --> 00:40:52,867
Only four would surviveuntil the following morning.
651
00:40:53,033 --> 00:40:55,867
In addition to the foursurvivors, the rescue teams
652
00:40:56,033 --> 00:40:57,000
find a camera.
653
00:40:57,166 --> 00:40:59,266
On it were photos
from the final moments
654
00:40:59,433 --> 00:41:01,266
inside Flight 123.
655
00:41:01,433 --> 00:41:11,333
[speaking French]
656
00:41:21,567 --> 00:41:26,000
Aviation is often quoted as
the safest form of transport,
657
00:41:26,166 --> 00:41:28,033
and the statistics
play that out.
658
00:41:28,200 --> 00:41:30,867
But whenever there is
an accident, sadly,
659
00:41:31,033 --> 00:41:33,667
they're often examples
of fatal engineering.
660
00:41:37,367 --> 00:41:41,266
After the accident, Boeing tooksteps to modify the hydraulic
661
00:41:41,266 --> 00:41:44,467
systems of its planes in orderto prevent such a tragic
662
00:41:44,634 --> 00:41:47,333
scenario from happening again.
663
00:41:47,500 --> 00:41:51,066
This disaster also served asa true lesson on the importance
664
00:41:51,233 --> 00:41:54,533
of aircraft maintenance,a lesson for the entire
665
00:41:54,700 --> 00:41:56,233
aviation industry.
58920
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