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1
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JIM: What is going on out there?
2
00:00:05,372 --> 00:00:07,273
FLIGHT ATTENDANT:
Everyone, we're about
to evacuate the plane.
3
00:00:07,340 --> 00:00:08,708
Remain calm.
4
00:00:08,775 --> 00:00:11,344
JIM: I certainly knew
that with both engines on fire
5
00:00:11,411 --> 00:00:12,812
it was not going to go well.
6
00:00:12,879 --> 00:00:17,484
NARRATOR: 157 passengers
rush to escape a burning 737.
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00:00:17,550 --> 00:00:18,818
JIM: Let's go, let's go!
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00:00:20,387 --> 00:00:22,822
KIT: It goes up like a bomb.
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00:00:22,889 --> 00:00:25,392
♪
10
00:00:25,458 --> 00:00:27,861
NARRATOR: In the struggle
to explain the inferno,
11
00:00:27,927 --> 00:00:31,197
the smallest parts come
under intense scrutiny.
12
00:00:31,264 --> 00:00:34,033
The analysis leads to
a stunning discovery.
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00:00:34,100 --> 00:00:35,168
INVESTIGATOR: Where is it?
14
00:00:35,235 --> 00:00:37,771
BOB: It was a true breakthrough
in the investigation.
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00:00:37,837 --> 00:00:41,174
NARRATOR: The failure that
doomed China Airlines Flight 120
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00:00:41,241 --> 00:00:44,444
is putting more
lives in danger every day.
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00:00:44,511 --> 00:00:47,013
KIT: We really didn't
anticipate that there's a risk,
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00:00:47,080 --> 00:00:48,581
and it bit us.
19
00:00:49,048 --> 00:00:51,084
Flight attendant:
LADIES AND GENTLEMEN,
WE ARE STARTING OUR APPROACH.
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00:00:51,151 --> 00:00:52,352
Pilot: WE LOST BOTH ENGINES!
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00:00:52,419 --> 00:00:53,620
Flight attendant:
PUT THE MASK OVER YOUR NOSE.
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00:00:53,686 --> 00:00:54,554
EMERGENCY DESCENT.
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00:00:54,621 --> 00:00:55,622
Pilot: MAYDAY, MAYDAY.
24
00:00:55,688 --> 00:00:57,323
Flight attendant:
BRACE FOR IMPACT!
25
00:00:57,390 --> 00:00:58,625
Controller: I THINK I LOST ONE.
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00:00:58,691 --> 00:01:01,761
Man: INVESTIGATION STARTING
INTO THIS TRAGEDY...
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00:01:01,828 --> 00:01:03,329
Man: HE'S GONNA CRASH!
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♪
29
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NARRATOR: China
Airlines Flight 120
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00:01:19,312 --> 00:01:23,917
is on final
approach for landing.
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CPT. YU: Ladies and gentlemen,
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we're about to begin our descent
into Okinawa Naha Airport.
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Please give the flight
attendants your full cooperation
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00:01:32,058 --> 00:01:35,395
as they prepare
the cabin for landing.
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NARRATOR: The Captain is
47-year-old Yu Chien-kou.
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CPT. YU: What's the
weather for approach?
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FO. TSENG: The ceiling is 8,000
feet. Winds at eight knots.
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NARRATOR: The first officer
is 26-year-old Tseng Ta-wei.
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00:01:49,075 --> 00:01:52,412
The pilots have more than 8,500
hours of flight experience
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00:01:52,479 --> 00:01:53,413
between them.
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00:01:53,480 --> 00:01:54,714
CPT. YU: Almost
straight down the pipe.
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00:01:54,781 --> 00:01:56,015
FO. TSENG: Yes, sir.
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NARRATOR: Landing this
Boeing 737 should be routine.
44
00:02:00,253 --> 00:02:02,522
KIT: The 737 is probably
the most popular airframe
45
00:02:02,589 --> 00:02:03,756
in the world.
46
00:02:03,823 --> 00:02:06,659
It's flown by most pilots as
they start out in their careers.
47
00:02:06,726 --> 00:02:10,964
It's a short-range
domestic airplane.
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00:02:11,030 --> 00:02:13,700
NARRATOR: Flight 120 is a
one-hour journey from Taiwan
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00:02:13,766 --> 00:02:20,139
to the southern
Japanese island of Okinawa.
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00:02:20,206 --> 00:02:22,675
This morning,
there are 157 passengers
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00:02:22,742 --> 00:02:24,777
and eight crew on board.
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00:02:24,844 --> 00:02:28,548
FLIGHT ATTENDANT:
Please put your tray up
and fasten your seat belt.
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00:02:28,615 --> 00:02:31,451
NARRATOR:
Jim Caruso is a medical
examiner for the U.S. Navy
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00:02:31,518 --> 00:02:35,021
stationed in Okinawa.
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00:02:35,088 --> 00:02:37,790
He and his family are on the
last leg of a long trip home
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from vacation.
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00:02:39,626 --> 00:02:42,529
JIM: The family was returning
from Brisbane, Australia.
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00:02:42,595 --> 00:02:46,232
We had done probably 12
or 14 days on vacation,
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00:02:46,299 --> 00:02:48,902
and we were hoping
to be home for lunch.
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00:02:48,968 --> 00:02:51,571
NARRATOR: Living in Okinawa has
given the Carusos the chance
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00:02:51,638 --> 00:02:54,574
to travel through much of Asia.
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00:02:54,641 --> 00:02:58,978
JIM: We got to see China, Hong
Kong, mainland Japan, Korea.
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00:02:59,045 --> 00:03:06,219
We had made use of our location
to experience the area.
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00:03:06,286 --> 00:03:08,955
NARRATOR: Naha Airport sits
at the southern end of Okinawa,
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00:03:09,022 --> 00:03:14,027
on the shore of
the East China Sea.
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00:03:14,093 --> 00:03:16,529
The pilots reconfigure
their plane as they slow down
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00:03:16,596 --> 00:03:18,831
and descend for landing.
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00:03:18,898 --> 00:03:21,768
CPT. YU: Let's go to flaps 25.
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00:03:21,834 --> 00:03:23,736
FO. TSENG: Flaps 25.
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00:03:23,803 --> 00:03:25,972
NARRATOR: They deploy flaps
from the wing's back edge,
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00:03:26,039 --> 00:03:29,976
along with slats
from the front edge.
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00:03:30,043 --> 00:03:34,047
These devices keep the
plane airborne at lower speeds.
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00:03:34,113 --> 00:03:35,315
KIT: When we start configuring,
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00:03:35,381 --> 00:03:37,050
we begin to put
out flaps and slats,
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00:03:37,116 --> 00:03:40,286
which extend the area of
the wing and give us more lift
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00:03:40,353 --> 00:03:43,156
and allow us to fly slower.
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00:03:43,222 --> 00:03:45,491
And of course the
landing and touchdown itself
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00:03:45,558 --> 00:03:49,262
are the most
complicated part of the flight.
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00:03:49,329 --> 00:03:53,900
NARRATOR: They're now less
than a minute from the runway.
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00:03:53,967 --> 00:03:57,203
JIM: Okay, honey. You
have to remain in your seat.
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00:03:57,270 --> 00:03:59,806
JIM: I think everybody was
looking forward to landing,
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00:03:59,872 --> 00:04:03,876
getting off the airplane and
getting back to regular life.
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00:04:10,683 --> 00:04:13,186
AUTOMATION: 30, 20, 10.
84
00:04:16,990 --> 00:04:19,492
NARRATOR: It's a
textbook landing.
85
00:04:26,099 --> 00:04:27,100
CPT. YU: Flaps up.
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00:04:33,439 --> 00:04:36,576
JIM: Once you're landed
you figure you're home free.
87
00:04:36,643 --> 00:04:41,080
The taxi is usually routine.
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00:04:41,147 --> 00:04:44,217
CPT. YU:
After landing checklist.
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00:04:44,283 --> 00:04:49,956
FO. TSENG: Speed brakes.
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00:04:50,023 --> 00:04:52,291
NARRATOR: All that's left for
the China Airlines pilots
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00:04:52,358 --> 00:04:54,327
is to park the plane.
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00:04:54,394 --> 00:04:55,895
FO. TSENG: Engine start levers.
93
00:04:55,962 --> 00:04:58,831
CPT. YU: Engine
start levers cut off.
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00:04:58,898 --> 00:05:02,835
NARRATOR: With the engines
off they can finally relax.
95
00:05:02,902 --> 00:05:06,372
KIT: The pilot is relieved.
He's no longer at risk.
96
00:05:06,439 --> 00:05:08,474
A catastrophic
event after you're parked
97
00:05:08,541 --> 00:05:13,446
is almost non-existent.
98
00:05:13,513 --> 00:05:18,518
FO. TSENG: Seat belts.
CPT. YU: Seat belts off.
99
00:05:18,584 --> 00:05:20,353
JIM: The biggest challenge
ahead of you from there
100
00:05:20,420 --> 00:05:23,289
is making sure you
can get through customs.
101
00:05:23,356 --> 00:05:25,758
No one ever expects
anything to go wrong,
102
00:05:25,825 --> 00:05:28,628
especially once the
engines are turned off.
103
00:05:28,695 --> 00:05:30,096
NARRATOR: But one
passenger has noticed
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00:05:30,163 --> 00:05:33,499
that something's not right.
105
00:05:33,566 --> 00:05:36,269
JIM: My wife was next to a woman
106
00:05:36,335 --> 00:05:37,937
who made some
sort of exclamation
107
00:05:38,004 --> 00:05:40,740
towards the engine
on the right side.
108
00:05:40,807 --> 00:05:48,448
FEMALE PASSENGER:
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00:05:48,514 --> 00:05:50,249
JIM: What's going on?
110
00:05:50,316 --> 00:05:52,752
JIM: There was some
smoke coming from that engine.
111
00:05:52,819 --> 00:05:55,054
That was the first
sign that something
112
00:05:55,121 --> 00:05:56,656
was out of the ordinary.
113
00:05:56,723 --> 00:05:59,425
JIM: What is going on out there?
114
00:05:59,492 --> 00:06:02,862
FO. TSENG: Anti-ice,
off. Start switches, off.
115
00:06:02,929 --> 00:06:06,199
NARRATOR:
The pilots are finishing
the shut-down checklist.
116
00:06:06,265 --> 00:06:07,834
FO. TSENG: Transponder T-CAS.
117
00:06:07,900 --> 00:06:13,072
CPT. YU: Hey! What is this?
118
00:06:13,139 --> 00:06:14,273
FO. TSENG: What's happening?
119
00:06:14,340 --> 00:06:16,876
NARRATOR: Just when they thought
they were safely parked...
120
00:06:16,943 --> 00:06:20,213
GROUND CREW: Cockpit,
ground. Number 2 engine fire.
121
00:06:20,279 --> 00:06:23,649
NARRATOR: ...a radio call alerts
them to an urgent danger.
122
00:06:23,716 --> 00:06:26,252
Their plane is on fire.
123
00:06:26,319 --> 00:06:27,587
FO. TSENG:
Attention, crew on station.
124
00:06:27,653 --> 00:06:29,322
Attention, crew on station.
125
00:06:29,388 --> 00:06:31,390
KIT: Bringing the flight
attendants to their station
126
00:06:31,457 --> 00:06:33,559
tells them that what
might likely be next
127
00:06:33,626 --> 00:06:36,696
would be an
emergency evacuation.
128
00:06:36,763 --> 00:06:38,765
RADIO CALL: Dynasty 1-2-0,
we are calling a fire truck.
129
00:06:38,831 --> 00:06:41,267
Remain on standby.
130
00:06:41,334 --> 00:06:45,438
FO. TSENG: We have
a wheel fire. Please.
131
00:06:45,505 --> 00:06:47,507
FEMALE PASSENGER:
132
00:06:47,573 --> 00:06:50,042
FO. TSENG: Cabin crew,
prepare for evacuation.
133
00:06:50,109 --> 00:06:51,744
Prepare for evacuation.
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00:06:51,811 --> 00:06:55,047
♪
135
00:06:55,114 --> 00:06:56,282
FLIGHT ATTENDANT:
Everyone, remain calm.
136
00:06:56,349 --> 00:07:00,787
We're about to evacuate
the plane. Remain calm.
137
00:07:00,853 --> 00:07:04,524
NARRATOR: Fear begins to
spread throughout the cabin.
138
00:07:04,590 --> 00:07:07,560
Outside, the fire
is getting worse.
139
00:07:07,627 --> 00:07:12,165
JIM: The engine on my side also
started smoking and flaming.
140
00:07:12,231 --> 00:07:15,168
So now we had
both wings on fire.
141
00:07:15,234 --> 00:07:18,538
And at that point
people began to panic.
142
00:07:18,604 --> 00:07:21,107
FLIGHT ATTENDANT:
Remain calm! No pushing!
143
00:07:24,877 --> 00:07:27,413
JIM: I had no idea at that point
how things would play out,
144
00:07:27,480 --> 00:07:30,383
but I certainly knew that
with both engines on fire
145
00:07:30,449 --> 00:07:34,253
it was not going to go well.
146
00:07:36,289 --> 00:07:39,025
FO. TSENG: Parking brakes.
Speed brakes. It's that lever.
147
00:07:39,091 --> 00:07:40,893
NARRATOR: The pilots know they
need to get their passengers
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00:07:40,960 --> 00:07:46,599
off the plane before
flames reach the fuel tanks.
149
00:07:46,666 --> 00:07:49,969
But they can't open
the cabin doors yet.
150
00:07:50,036 --> 00:07:52,572
CPT. YU: Engine fire
warning switches. Override.
151
00:07:52,638 --> 00:07:55,808
NARRATOR: They must
follow an evacuation checklist.
152
00:07:55,875 --> 00:07:58,711
KIT: We want the pilots to
grab the list, simply read it
153
00:07:58,778 --> 00:07:59,712
and do it.
154
00:07:59,779 --> 00:08:01,781
No wondering what step is next,
155
00:08:01,848 --> 00:08:04,951
because the sequence of
the steps are very important.
156
00:08:05,017 --> 00:08:09,388
CPT. YU: Pull and rotate.
157
00:08:09,455 --> 00:08:10,590
FLIGHT ATTENDANT:
Everybody remain calm.
158
00:08:10,656 --> 00:08:15,494
Do not bring your
luggage or personal belongings.
159
00:08:15,561 --> 00:08:21,200
NARRATOR: Seconds feel like
hours as the crisis escalates.
160
00:08:21,267 --> 00:08:24,604
Finally, the pilots are
ready to open the doors.
161
00:08:24,670 --> 00:08:26,806
FO. TSENG: Evacuation
required now. Required.
162
00:08:26,873 --> 00:08:30,743
♪
163
00:08:30,810 --> 00:08:32,211
FLIGHT ATTENDANT: No
pushing. No pushing.
164
00:08:32,278 --> 00:08:33,880
Please keep moving forward.
165
00:08:33,946 --> 00:08:37,316
NARRATOR: But it will take
time for all 157 passengers
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00:08:37,383 --> 00:08:40,519
to make it to the exit.
167
00:08:40,586 --> 00:08:43,723
George Ishizaki is
watching the unfolding disaster
168
00:08:43,789 --> 00:08:46,926
from inside the
airport terminal.
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00:08:46,993 --> 00:08:51,063
GEORGE: I just happened to
have my camcorder with me.
170
00:08:51,130 --> 00:08:54,133
I thought, oh my
god, what is happening?
171
00:09:03,676 --> 00:09:05,044
FLIGHT ATTENDANT:
Keep moving forward.
172
00:09:05,111 --> 00:09:07,046
NARRATOR: With the
fire growing more intense,
173
00:09:07,113 --> 00:09:08,948
time is running out.
174
00:09:09,015 --> 00:09:10,583
JIM: Let's go. Let's go!
175
00:09:10,650 --> 00:09:13,653
JIM: We were quite a
ways back from any exit
176
00:09:13,719 --> 00:09:16,122
since the over-wing
exits were useless.
177
00:09:16,188 --> 00:09:19,392
So my focus was really to
get the kids moving forward
178
00:09:19,458 --> 00:09:21,394
and off the aircraft.
179
00:09:21,460 --> 00:09:27,633
FEMALE PASSENGER (In distress):
180
00:09:27,700 --> 00:09:29,435
JIM: Go ahead. Go
ahead, all right?
181
00:09:29,502 --> 00:09:32,271
NARRATOR: Jim Caruso stays
behind to help other passengers
182
00:09:32,338 --> 00:09:34,740
get off the burning plane.
183
00:09:34,807 --> 00:09:36,976
JIM: I don't
actually remember hesitating.
184
00:09:37,043 --> 00:09:40,079
It may have been a little
difficult to make that decision
185
00:09:40,146 --> 00:09:42,815
since the kids were
already moving forward.
186
00:09:42,882 --> 00:09:46,385
FLIGHT ATTENDANT: Hey, no
pushing. Keep moving forward.
187
00:09:52,658 --> 00:09:55,861
GEORGE: The smoke
actually started building, and
188
00:09:55,928 --> 00:09:58,931
that's when everything started
happening really quickly.
189
00:10:03,769 --> 00:10:07,239
♪
190
00:10:07,306 --> 00:10:10,076
NARRATOR: Jim Caruso is
separated from his family.
191
00:10:10,142 --> 00:10:14,914
The heat and smoke are getting
worse. He hears a cry for help.
192
00:10:14,981 --> 00:10:16,582
FEMALE PASSENGER:
193
00:10:16,649 --> 00:10:20,353
JIM: The woman behind me pointed
towards the overhead bin.
194
00:10:20,419 --> 00:10:22,588
I was concerned if
she was pointing towards
195
00:10:22,655 --> 00:10:24,256
flames coming in.
196
00:10:24,323 --> 00:10:25,358
FEMALE PASSENGER:
197
00:10:25,424 --> 00:10:28,227
JIM: I looked up and I
saw a pair of crutches.
198
00:10:36,836 --> 00:10:39,171
GEORGE: Everybody was
just sliding down the slides,
199
00:10:39,238 --> 00:10:42,742
and once they got on the ground
they were just scrambling.
200
00:10:44,243 --> 00:10:45,911
♪
201
00:10:45,978 --> 00:10:48,180
JIM: Once the smoke
and fire started building,
202
00:10:48,247 --> 00:10:51,017
the cabin became rather warm.
203
00:10:51,083 --> 00:10:52,918
I do recall some of the
windows actually cracking
204
00:10:52,985 --> 00:10:56,789
from the heat.
205
00:10:56,856 --> 00:10:59,859
NARRATOR: Finally,
they make it to the exit.
206
00:11:06,132 --> 00:11:09,668
♪
207
00:11:09,735 --> 00:11:12,505
The plane has been burning
for close to three minutes.
208
00:11:12,571 --> 00:11:15,007
It could explode at any moment.
209
00:11:15,074 --> 00:11:17,243
FLIGHT ATTENDANT:
210
00:11:17,309 --> 00:11:19,245
Captain, all
passengers are evacuated.
211
00:11:19,311 --> 00:11:20,813
You're the last ones.
212
00:11:24,517 --> 00:11:26,519
CPT. YU: We
gotta get out of here.
213
00:11:30,689 --> 00:11:32,725
KIT: Typically, the captain
will stay until everybody's off
214
00:11:32,792 --> 00:11:37,797
and he will verify
that the airplane is empty.
215
00:11:37,863 --> 00:11:41,067
NARRATOR: The pilots have put
their passengers' safety first.
216
00:11:41,133 --> 00:11:43,869
But now it may be
too late for them.
217
00:11:43,936 --> 00:11:45,671
CPT. YU: We're going to have to
climb out through the window.
218
00:11:45,738 --> 00:11:46,605
You first.
219
00:11:46,672 --> 00:11:47,740
FO. TSENG: Yes, sir.
220
00:11:47,807 --> 00:11:49,708
NARRATOR: All 737
cockpits are equipped
221
00:11:49,775 --> 00:11:52,278
with an emergency escape rope.
222
00:11:52,344 --> 00:11:55,815
It's designed to help pilots
exit through the side window,
223
00:11:55,881 --> 00:11:58,017
but it's no easy maneuver.
224
00:11:58,084 --> 00:12:00,786
KIT: Exiting the airplane is
more difficult than it sounds.
225
00:12:00,853 --> 00:12:05,891
It's a relatively small window.
Going down the rope has a risk.
226
00:12:05,958 --> 00:12:09,829
♪
227
00:12:09,895 --> 00:12:12,298
Then...
228
00:12:13,632 --> 00:12:19,572
WITNESS: Oh.
Whoa. Whoa. Oh my god!
229
00:12:19,638 --> 00:12:24,343
GEORGE: You felt a huge kaboom.
230
00:12:24,410 --> 00:12:28,180
I've never felt
anything like that.
231
00:12:28,247 --> 00:12:31,016
JIM: We actually could
feel the ground shake.
232
00:12:31,083 --> 00:12:34,653
♪
233
00:12:34,720 --> 00:12:37,356
NARRATOR: Passengers run to
safety as a fiery explosion
234
00:12:37,423 --> 00:12:41,694
engulfs the plane
they just escaped.
235
00:12:41,760 --> 00:12:45,197
The fate of the
pilots is still unknown.
236
00:12:45,264 --> 00:12:47,500
JIM: As I looked back
after the first explosion,
237
00:12:47,566 --> 00:12:50,669
I recall crew members
fast-roping, as it were,
238
00:12:50,736 --> 00:12:53,672
out of the cockpit.
239
00:12:53,739 --> 00:12:57,443
NARRATOR: The force of the blast
overpowers the first officer.
240
00:12:57,510 --> 00:13:00,980
GEORGE: He dropped down from the
height of the cockpit window
241
00:13:01,046 --> 00:13:02,615
onto the ground.
242
00:13:02,681 --> 00:13:04,650
NARRATOR: Incredibly, he's
able to get up and run away
243
00:13:04,717 --> 00:13:11,056
from the flames. The
captain quickly follows.
244
00:13:11,123 --> 00:13:12,625
GEORGE: It was
good that he did that,
245
00:13:12,691 --> 00:13:15,728
because the fire
just gutted the airplane.
246
00:13:15,794 --> 00:13:18,931
NARRATOR: More
explosions rock the airplane.
247
00:13:18,998 --> 00:13:20,599
GEORGE: The
fuselage I guess melted.
248
00:13:20,666 --> 00:13:23,035
The back half just
kind of fell to the ground.
249
00:13:24,336 --> 00:13:28,240
NARRATOR: Finally, fire
trucks arrive on the scene.
250
00:13:28,307 --> 00:13:30,609
JIM: Everybody had exited
the aircraft at that point
251
00:13:30,676 --> 00:13:33,679
and was
gathering in the terminal.
252
00:13:38,050 --> 00:13:40,653
It was a huge
relief to have the kids
253
00:13:40,719 --> 00:13:43,222
and my wife and I together.
254
00:13:43,289 --> 00:13:45,524
We certainly were looking
back at the aircraft again
255
00:13:45,591 --> 00:13:50,029
in amazement.
256
00:13:50,095 --> 00:13:53,632
NARRATOR: Fire on an airplane
can quickly become lethal.
257
00:13:53,699 --> 00:13:58,003
Incredibly, on Flight
120, all 165 people on board
258
00:13:58,070 --> 00:14:00,906
have escaped unharmed.
259
00:14:00,973 --> 00:14:02,841
KIT: I've never
heard of any evacuation
260
00:14:02,908 --> 00:14:05,044
where somebody wasn't hurt.
261
00:14:05,110 --> 00:14:07,880
To get this many people off
in such a dire circumstance
262
00:14:07,947 --> 00:14:12,218
in a very short period of time
with no injuries is miraculous.
263
00:14:12,284 --> 00:14:14,587
♪
264
00:14:14,653 --> 00:14:15,988
NARRATOR: If
there's a next time,
265
00:14:16,055 --> 00:14:19,191
passengers may not be so lucky.
266
00:14:19,258 --> 00:14:21,160
Pressure to figure
out what happened falls
267
00:14:21,227 --> 00:14:25,698
on an international team
of air crash investigators.
268
00:14:25,764 --> 00:14:30,869
THOMAS: Okay. Let's get to work.
269
00:14:30,936 --> 00:14:32,905
NARRATOR: They need to
explain how an airliner
270
00:14:32,972 --> 00:14:36,175
that had landed safely
and turned off its engines
271
00:14:36,242 --> 00:14:38,244
suddenly burst into flames.
272
00:14:40,646 --> 00:14:44,550
THOMAS: We have no clue.
We do not know what happened.
273
00:14:44,617 --> 00:14:47,853
We tried to find out from
the wreckage that remained
274
00:14:47,920 --> 00:14:51,090
still on the apron.
275
00:14:51,156 --> 00:14:53,359
BOB: Normally
fires occur in-flight,
276
00:14:53,425 --> 00:14:55,494
perhaps during taxi sometimes,
277
00:14:55,561 --> 00:14:59,898
but rarely in a parking spot
after the engines are shut down.
278
00:14:59,965 --> 00:15:03,002
THOMAS: The challenge
for the investigator is,
279
00:15:03,068 --> 00:15:06,071
most of the evidence will
be destroyed by the fire.
280
00:15:10,776 --> 00:15:13,112
NARRATOR: Across the globe,
there are more than 5,000
281
00:15:13,178 --> 00:15:17,449
Boeing 737s in service.
282
00:15:17,516 --> 00:15:19,785
KIT: There's a 737
taking off and landing
283
00:15:19,852 --> 00:15:23,489
every three or four
seconds in the world.
284
00:15:23,555 --> 00:15:25,357
NARRATOR: If the
plane has a design flaw
285
00:15:25,424 --> 00:15:28,861
that somehow leads
to uncontainable fire,
286
00:15:28,927 --> 00:15:32,298
countless
passengers could be at risk.
287
00:15:32,364 --> 00:15:33,799
BOB: We were aware that the 737
288
00:15:33,866 --> 00:15:36,435
is probably the most
popular airliner out there.
289
00:15:36,502 --> 00:15:38,837
So there's a reason
once an accident occurs
290
00:15:38,904 --> 00:15:42,408
to try to figure out what
happened pretty darn quickly.
291
00:15:46,779 --> 00:15:48,080
♪
292
00:15:48,147 --> 00:15:50,382
NARRATOR: The search for
Flight 120's black boxes
293
00:15:50,449 --> 00:15:52,818
begins immediately.
294
00:15:52,885 --> 00:15:54,219
BOB: One of our
main goals initially
295
00:15:54,286 --> 00:15:56,288
is to try to find the
cockpit voice recorder
296
00:15:56,355 --> 00:15:58,223
and the flight data recorder.
297
00:15:58,290 --> 00:16:00,726
These are important,
because a lot of times
298
00:16:00,793 --> 00:16:03,295
they tell us what happened.
299
00:16:03,362 --> 00:16:04,596
NARRATOR: But
investigators know that
300
00:16:04,663 --> 00:16:06,465
after such an intense fire
301
00:16:06,532 --> 00:16:11,403
there's a chance the
black box data will be lost.
302
00:16:11,470 --> 00:16:13,739
They need other leads.
303
00:16:13,806 --> 00:16:15,441
BOB: Good investigators
don't rely totally
304
00:16:15,507 --> 00:16:17,476
on flight data
recorders, for instance,
305
00:16:17,543 --> 00:16:20,379
or cockpit voice recorders
because they can be destroyed.
306
00:16:20,446 --> 00:16:23,682
So we rely on witnesses
to tell us their impression
307
00:16:23,749 --> 00:16:26,285
of what happened.
308
00:16:26,352 --> 00:16:27,886
CPT. YU: Well, we
taxied off the runway
309
00:16:27,953 --> 00:16:30,689
down the apron to our
assigned parking spot.
310
00:16:30,756 --> 00:16:32,691
FO. TSENG: Once we parked,
we shut off the engines,
311
00:16:32,758 --> 00:16:36,495
and some time after that we
heard the aircraft was on fire.
312
00:16:36,562 --> 00:16:39,098
BOB: We needed to know
what type of fire it was,
313
00:16:39,164 --> 00:16:41,433
what the
ignition source would be,
314
00:16:41,500 --> 00:16:43,602
what the fuel source would be.
315
00:16:43,669 --> 00:16:47,773
Those were the areas of our main
questioning right off the bat.
316
00:16:47,840 --> 00:16:49,575
FO. TSENG: I radioed the
controller letting him know
317
00:16:49,641 --> 00:16:51,143
we had a wheel fire.
318
00:16:55,214 --> 00:16:57,649
NARRATOR: Investigators know
that if a wheel caught fire
319
00:16:57,716 --> 00:17:02,154
on Flight 120, there's
more than one possible cause.
320
00:17:02,221 --> 00:17:05,691
A deflated tire can
result in burning rubber.
321
00:17:05,758 --> 00:17:07,593
Overheated brake
pads could potentially
322
00:17:07,659 --> 00:17:10,095
ignite hydraulic fluid.
323
00:17:10,162 --> 00:17:11,296
BOB: In a wheel
well of an aircraft
324
00:17:11,363 --> 00:17:13,532
there are a lot
of hydraulic lines
325
00:17:13,599 --> 00:17:17,302
going to the landing gear
assemblies and things like that.
326
00:17:17,369 --> 00:17:19,405
Hydraulic fluid
is very flammable.
327
00:17:19,471 --> 00:17:22,341
If a hydraulic leak occurred
and it happened to drip
328
00:17:22,408 --> 00:17:26,412
onto a hot brake for
instance, well, there you go.
329
00:17:27,713 --> 00:17:29,915
CPT. YU: Hey. What is this?
FO. TSENG: We have a wheel fire.
330
00:17:29,982 --> 00:17:32,885
NARRATOR:
If the pilots are right
about where the fire started,
331
00:17:32,951 --> 00:17:39,658
investigators should
be able to find proof.
332
00:17:39,725 --> 00:17:42,094
They examine the
plane's right side wheel well
333
00:17:42,161 --> 00:17:44,897
and landing gear assembly.
334
00:17:44,963 --> 00:17:48,233
They find scorched wreckage,
but not enough to convince them
335
00:17:48,300 --> 00:17:51,003
that this is
where the fire began.
336
00:17:51,069 --> 00:17:52,538
BOB: Once we were
able to closely examine
337
00:17:52,604 --> 00:17:54,206
that part of the aircraft,
338
00:17:54,273 --> 00:17:56,842
we were very confident
that a wheel well fire per se
339
00:17:56,909 --> 00:17:58,277
did not occur.
340
00:17:58,343 --> 00:18:00,479
The seat of the fire
seemed to be forward
341
00:18:00,546 --> 00:18:03,115
and a little bit to the
right of the wheel well area.
342
00:18:03,182 --> 00:18:04,883
NARRATOR: It seems
the pilots were mistaken
343
00:18:04,950 --> 00:18:07,853
about the origins of the fire.
344
00:18:07,920 --> 00:18:10,222
Where it started
remains a mystery.
345
00:18:10,289 --> 00:18:14,293
♪
346
00:18:14,359 --> 00:18:17,663
Solving that mystery may
have just become easier.
347
00:18:17,729 --> 00:18:22,534
Investigators have recovered
the plane's black boxes.
348
00:18:22,601 --> 00:18:27,606
THOMAS:
The Japanese team retrieved
both the Boeing's CVR and FDR.
349
00:18:27,673 --> 00:18:31,243
THOMAS: Let's get
working on the FDR immediately.
350
00:18:31,310 --> 00:18:34,079
BOB: On modern 737s,
the flight data recorder
351
00:18:34,146 --> 00:18:37,015
has thousands of parameters,
352
00:18:37,082 --> 00:18:43,322
data bits that come in to
the recording device itself.
353
00:18:43,388 --> 00:18:46,492
It will take time to download
and verify all the data.
354
00:18:46,558 --> 00:18:51,029
♪
355
00:18:51,096 --> 00:18:53,165
NARRATOR: Meanwhile,
the charred fire scene
356
00:18:53,232 --> 00:18:57,936
continues to
challenge investigators.
357
00:18:58,003 --> 00:19:00,973
THOMAS: With all this heat
damage it's nearly impossible
358
00:19:01,039 --> 00:19:03,408
to tell where the fire started.
359
00:19:03,475 --> 00:19:04,877
NARRATOR: They're
almost certain the fire began
360
00:19:04,943 --> 00:19:08,881
on the right side of the
plane as witnesses reported.
361
00:19:08,947 --> 00:19:11,116
But where exactly?
362
00:19:11,183 --> 00:19:14,052
THOMAS: Wait a sec.
363
00:19:14,119 --> 00:19:17,523
NARRATOR: Scorched wires
provide a promising new lead.
364
00:19:17,589 --> 00:19:18,790
THOMAS: What do you think?
365
00:19:18,857 --> 00:19:22,461
NARRATOR: Did an electrical
fire destroy Flight 120?
366
00:19:22,528 --> 00:19:28,667
Serious electrical failures
are rare, but not unheard of.
367
00:19:28,734 --> 00:19:31,970
In 1998, the cockpit
of Swissair Flight 111
368
00:19:32,037 --> 00:19:35,240
began filling with
smoke shortly after takeoff.
369
00:19:35,307 --> 00:19:37,276
The pilots tried to
make an emergency landing
370
00:19:37,342 --> 00:19:41,013
in Halifax, Canada.
They never made it.
371
00:19:41,079 --> 00:19:43,582
Their plane disappeared
into the Atlantic Ocean,
372
00:19:43,649 --> 00:19:47,419
killing all 229 people onboard.
373
00:19:47,486 --> 00:19:49,688
Investigators found
that an electrical fault
374
00:19:49,755 --> 00:19:51,490
in the entertainment system
375
00:19:51,557 --> 00:19:55,294
almost certainly sparked
the fire that doomed the plane.
376
00:19:59,565 --> 00:20:03,235
THOMAS: Okay.
Let's see what we got.
377
00:20:03,302 --> 00:20:05,337
NARRATOR: If the
fire aboard Flight 120
378
00:20:05,404 --> 00:20:07,272
was caused by faulty wiring,
379
00:20:07,339 --> 00:20:10,375
investigators may now
be able to confirm it.
380
00:20:10,442 --> 00:20:13,979
They've successfully
downloaded the black box data.
381
00:20:14,046 --> 00:20:17,416
Any electrical problem or
failure in any onboard system
382
00:20:17,482 --> 00:20:20,118
should show up in the data.
383
00:20:20,185 --> 00:20:22,821
BOB: Almost every system
on the aircraft is recorded.
384
00:20:22,888 --> 00:20:24,990
Its status is recorded.
385
00:20:25,057 --> 00:20:26,258
So we looked
very quickly through
386
00:20:26,325 --> 00:20:30,329
these hundreds of
electrical possibilities
387
00:20:30,395 --> 00:20:32,264
and we found nothing.
388
00:20:32,331 --> 00:20:35,000
THOMAS: It wasn't electrical.
389
00:20:35,067 --> 00:20:37,569
NARRATOR: The
analysis comes up empty.
390
00:20:37,636 --> 00:20:40,172
THOMAS: At that time we
can rule out some wheel fire
391
00:20:40,238 --> 00:20:42,741
or some other electrical fire.
392
00:20:49,214 --> 00:20:50,649
NARRATOR: Investigators
turn their attention
393
00:20:50,716 --> 00:20:55,087
to the aircraft's right engine.
394
00:20:55,153 --> 00:20:58,023
In flight, the
CFM-56 power plant
395
00:20:58,090 --> 00:20:59,725
generates internal
temperatures of more
396
00:20:59,791 --> 00:21:06,598
than 2,000 degrees Fahrenheit,
hotter than molten lava.
397
00:21:06,665 --> 00:21:10,502
Could an engine fire
have sparked the inferno?
398
00:21:10,569 --> 00:21:14,272
BOB: We of course looked at
the engines very carefully,
399
00:21:14,339 --> 00:21:15,474
the right engine especially
400
00:21:15,540 --> 00:21:18,043
because there was a lot
of fire damage around it.
401
00:21:18,110 --> 00:21:20,278
It was fairly easy to
look inside the engine
402
00:21:20,345 --> 00:21:22,814
and examine the
core, so to speak,
403
00:21:22,881 --> 00:21:26,551
where all the damage in an
engine failure usually occurs.
404
00:21:26,618 --> 00:21:29,121
And we found nothing wrong.
405
00:21:34,226 --> 00:21:36,628
The engine was damaged
externally but not internally,
406
00:21:36,695 --> 00:21:43,201
so we eliminated it
as a possible factor.
407
00:21:43,268 --> 00:21:47,506
THOMAS: What could have
burned this entire plane down?
408
00:21:47,572 --> 00:21:50,042
NARRATOR: The
investigation has hit a wall.
409
00:21:50,108 --> 00:21:53,311
The cause of the catastrophic
fire remains unknown,
410
00:21:53,378 --> 00:21:59,117
while every day thousands
of 737s continue to fly.
411
00:21:59,184 --> 00:22:00,919
There's growing
pressure on investigators
412
00:22:00,986 --> 00:22:02,854
to find the answer.
413
00:22:02,921 --> 00:22:05,490
BOB: We knew we had a little bit
of detective work ahead of us
414
00:22:05,557 --> 00:22:07,059
and we pressed on.
415
00:22:11,797 --> 00:22:12,597
♪
416
00:22:14,966 --> 00:22:17,002
NARRATOR: The video
capturing the fiery destruction
417
00:22:17,069 --> 00:22:19,204
of China Airlines Flight 120
418
00:22:19,271 --> 00:22:20,806
could provide
investigators with clues
419
00:22:20,872 --> 00:22:23,375
to what started the fire.
420
00:22:27,679 --> 00:22:29,548
THOMAS: Whoa.
421
00:22:29,614 --> 00:22:31,483
NARRATOR: The footage
reveals just how quickly
422
00:22:31,550 --> 00:22:34,319
the flames spread
through the passenger jet.
423
00:22:34,386 --> 00:22:38,390
But for investigators, the
most important clue is missing.
424
00:22:38,457 --> 00:22:40,659
The recording hasn't
captured the critical moment
425
00:22:40,726 --> 00:22:44,029
the fire started.
426
00:22:44,096 --> 00:22:48,233
THOMAS: From the
video, we can only understand
427
00:22:48,300 --> 00:22:51,970
there was fire and
the location of the fire
428
00:22:52,037 --> 00:22:56,875
and it seems that something
was feeding to the fire.
429
00:22:56,942 --> 00:23:02,948
But we cannot understand why.
430
00:23:03,014 --> 00:23:05,183
♪
431
00:23:05,250 --> 00:23:09,654
NARRATOR: Investigators
widen the search for leads.
432
00:23:09,721 --> 00:23:11,389
THOMAS: What did you see?
433
00:23:11,456 --> 00:23:13,992
NARRATOR: The effort pays off
when an airport ground worker
434
00:23:14,059 --> 00:23:17,229
provides a critical detail.
435
00:23:17,295 --> 00:23:19,498
BOB: A ramp worker on the
right side of the aircraft
436
00:23:19,564 --> 00:23:23,001
said very distinctly
that he saw a liquid
437
00:23:23,068 --> 00:23:25,437
running down the
leading edge of the right wing
438
00:23:25,504 --> 00:23:28,173
before the fire broke out.
439
00:23:28,240 --> 00:23:31,143
THOMAS: Thanks.
440
00:23:31,209 --> 00:23:33,044
NARRATOR: Fluid leaking
from this part of the wing
441
00:23:33,111 --> 00:23:37,616
of the aircraft can be
only one thing: jet fuel.
442
00:23:42,621 --> 00:23:47,359
The 737 holds
4,390 gallons of fuel,
443
00:23:47,425 --> 00:23:48,827
much of it in tanks located
444
00:23:48,894 --> 00:23:52,597
inside the plane's
two massive wings.
445
00:23:52,664 --> 00:23:56,234
BOB: When we figured out that an
actual fuel leak had occurred,
446
00:23:56,301 --> 00:23:57,569
it was a breakthrough,
447
00:23:57,636 --> 00:24:01,606
a true breakthrough
in the investigation.
448
00:24:01,673 --> 00:24:07,979
We now needed to
know why it originated.
449
00:24:08,046 --> 00:24:12,384
THOMAS: We know the fuel
was leaking, but from where?
450
00:24:12,450 --> 00:24:15,053
A fuel line?
451
00:24:15,120 --> 00:24:17,556
NARRATOR: Finding solid evidence
amongst the burnt remains
452
00:24:17,622 --> 00:24:20,625
of the plane's fuel
system won't be easy.
453
00:24:24,629 --> 00:24:27,799
The Boeing 737-800
has high-pressure pumps
454
00:24:27,866 --> 00:24:29,835
inside the wing.
455
00:24:29,901 --> 00:24:34,472
They deliver 200 gallons of
fuel per hour to the engine.
456
00:24:34,539 --> 00:24:37,909
All that fuel flows
through flexible pipes.
457
00:24:37,976 --> 00:24:41,012
Could one of those
fuel pipes be the culprit?
458
00:24:41,079 --> 00:24:42,948
BOB: Fuel lines are
probably in a sense
459
00:24:43,014 --> 00:24:45,851
the most vulnerable
part of a fuel system.
460
00:24:45,917 --> 00:24:48,653
They take bends and
sometimes they're exposed
461
00:24:48,720 --> 00:24:51,723
where they could get knocked
or punctured by something.
462
00:24:51,790 --> 00:24:55,026
So we tried to trace the entire
fuel system of the aircraft.
463
00:24:55,093 --> 00:25:02,834
♪
464
00:25:02,901 --> 00:25:04,870
NARRATOR: It's another dead end.
465
00:25:04,936 --> 00:25:07,205
THOMAS: It
wasn't the fuel lines.
466
00:25:07,272 --> 00:25:12,143
NARRATOR: None of the
fuel lines are ruptured.
467
00:25:12,210 --> 00:25:13,478
BOB: We had a
lot of fire damage,
468
00:25:13,545 --> 00:25:17,449
but the fuel lines that we
examined seemed to be intact
469
00:25:17,515 --> 00:25:19,417
and functional.
470
00:25:19,484 --> 00:25:22,854
NARRATOR: Investigators
still can't explain the fire.
471
00:25:22,921 --> 00:25:24,789
They know enough fuel
leaked from the plane
472
00:25:24,856 --> 00:25:29,294
to feed the flames, but they
don't know where it came from.
473
00:25:29,361 --> 00:25:31,696
BOB: Once we
eliminated fuel lines per se
474
00:25:31,763 --> 00:25:35,100
as a possible problem,
475
00:25:35,166 --> 00:25:37,035
pretty much the only
thing out in that area
476
00:25:37,102 --> 00:25:40,805
that could have gone wrong is
a leak in the fuel tank itself.
477
00:25:40,872 --> 00:25:44,376
NARRATOR: The plane's fuel tanks
are made from aluminum alloy
478
00:25:44,442 --> 00:25:48,213
and designed to withstand
the rigors of flight for years.
479
00:25:48,280 --> 00:25:51,182
They should never crack or leak.
480
00:25:51,249 --> 00:25:52,284
Examining them
481
00:25:52,350 --> 00:25:55,987
presents one of the most
difficult challenges yet.
482
00:25:56,054 --> 00:26:00,425
They hope a tool called a
borescope will do the trick.
483
00:26:00,492 --> 00:26:04,195
It's a small camera that
can peer into tight spaces.
484
00:26:04,262 --> 00:26:05,497
It gives them a unique view
485
00:26:05,563 --> 00:26:08,566
inside the plane's
right wing fuel tank.
486
00:26:16,508 --> 00:26:18,910
What it reveals
changes the entire course
487
00:26:18,977 --> 00:26:22,948
of this investigation.
488
00:26:23,014 --> 00:26:25,016
THOMAS: Whoa.
Would you look at that?
489
00:26:25,083 --> 00:26:26,785
BOB: All of a
sudden, clear as a bell,
490
00:26:26,851 --> 00:26:32,624
we saw this bolt sticking
out of the fuel tank itself.
491
00:26:32,691 --> 00:26:36,561
Where the bolt came
from is a complete mystery,
492
00:26:36,628 --> 00:26:38,163
but it has ruptured the tank
493
00:26:38,229 --> 00:26:41,333
right where the ground
worker spotted leaking fuel.
494
00:26:41,399 --> 00:26:43,768
BOB: It's hard to describe
how significant this was.
495
00:26:43,835 --> 00:26:49,074
I mean, this was the
core of the investigation.
496
00:26:49,140 --> 00:26:51,409
Now we knew what happened.
497
00:26:51,476 --> 00:26:53,478
The rest of the investigation
was trying to figure out
498
00:26:53,545 --> 00:26:56,781
why this occurred.
499
00:26:56,848 --> 00:26:58,550
NARRATOR: A punctured
fuel tank was the cause
500
00:26:58,616 --> 00:27:04,356
of one of the most infamous
air crashes in history.
501
00:27:04,422 --> 00:27:08,326
A supersonic Air France Concorde
burst into flames on takeoff
502
00:27:08,393 --> 00:27:13,431
after running over a piece
of metal debris on the runway.
503
00:27:13,498 --> 00:27:16,134
Did a similar scenario
lead to the total destruction
504
00:27:16,201 --> 00:27:20,705
of China Airlines Flight 120?
505
00:27:20,772 --> 00:27:23,908
THOMAS: Okay. We need
to cut into this wing.
506
00:27:23,975 --> 00:27:25,977
NARRATOR: Investigators
need to get a closer look
507
00:27:26,044 --> 00:27:30,949
at the mysterious bolt that
made a hole in the fuel tank.
508
00:27:31,016 --> 00:27:33,385
BOB: The investigator
in charge said, yep,
509
00:27:33,451 --> 00:27:36,454
now's the time to start
cutting into that thing.
510
00:27:39,457 --> 00:27:49,434
♪
511
00:27:49,501 --> 00:27:56,274
♪
512
00:27:56,341 --> 00:27:59,377
THOMAS: Okay. Got it.
513
00:27:59,444 --> 00:28:05,917
NARRATOR:
Now they need to figure
out where the bolt came from.
514
00:28:05,984 --> 00:28:12,757
They study schematics
of the 737 wing structure.
515
00:28:12,824 --> 00:28:14,159
BOB: We went
back to the drawings
516
00:28:14,225 --> 00:28:16,795
and went back to things
like maintenance records
517
00:28:16,861 --> 00:28:19,531
to try to figure out
exactly what it was.
518
00:28:19,597 --> 00:28:22,100
NARRATOR: They
soon get their answer.
519
00:28:31,376 --> 00:28:33,912
THOMAS: A downstop assembly.
520
00:28:33,978 --> 00:28:36,815
NARRATOR: The downstop assembly
is part of the slat mechanism
521
00:28:36,881 --> 00:28:39,584
on the wing's leading edge.
522
00:28:39,651 --> 00:28:44,155
CPT. YU: Let's go to flaps 25.
FO. TSENG: Flaps 25.
523
00:28:44,222 --> 00:28:46,091
NARRATOR: Pilots
extend flaps and slats
524
00:28:46,157 --> 00:28:50,662
during every
takeoff and landing.
525
00:28:50,728 --> 00:28:53,131
The downstop is fixed
to the end of a track
526
00:28:53,198 --> 00:28:55,867
that slides back and forth.
527
00:28:55,934 --> 00:28:59,437
The device prevents the slats
from moving too far forward.
528
00:28:59,504 --> 00:29:02,707
RODNEY: The downstop is there,
quite frankly, to stop it
529
00:29:02,774 --> 00:29:05,543
when it reaches its
maximum deployment length.
530
00:29:05,610 --> 00:29:10,014
If it didn't exist
then there would be no way
531
00:29:10,081 --> 00:29:15,587
to retain the
slat on the aircraft.
532
00:29:15,653 --> 00:29:17,388
NARRATOR: Investigators
have identified the piece
533
00:29:17,455 --> 00:29:20,959
that penetrated the fuel tank.
534
00:29:21,025 --> 00:29:22,760
They know it's not
from another plane,
535
00:29:22,827 --> 00:29:27,932
like the runway debris that
caused the Concorde disaster.
536
00:29:27,999 --> 00:29:32,170
But they have other important
questions that need answers.
537
00:29:32,237 --> 00:29:34,806
BOB: We had the assembly.
We knew it punctured the tank.
538
00:29:34,873 --> 00:29:36,674
Our next step was
trying to figure out
539
00:29:36,741 --> 00:29:39,244
how this could
possibly have occurred.
540
00:29:43,581 --> 00:29:47,485
♪
541
00:29:47,552 --> 00:29:50,288
NARRATOR: Investigators pore
over Boeing service documents
542
00:29:50,355 --> 00:29:56,961
to learn more about
downstop assemblies on the 737.
543
00:29:57,028 --> 00:29:58,963
They make a
surprising discovery.
544
00:29:59,030 --> 00:30:00,665
THOMAS: This has
happened before,
545
00:30:00,732 --> 00:30:03,835
and it's
happened more than once.
546
00:30:03,902 --> 00:30:08,306
♪
547
00:30:08,373 --> 00:30:10,074
BOB: There'd been
two previous instances
548
00:30:10,141 --> 00:30:15,480
of this device coming apart
and causing minor fuel leaks,
549
00:30:15,547 --> 00:30:19,484
but this was the first instance
of an actual destructive fire.
550
00:30:19,551 --> 00:30:23,555
In both previous instances,
parts from a downstop assembly
551
00:30:23,621 --> 00:30:29,761
punctured a fuel tank,
just like on Flight 120.
552
00:30:29,827 --> 00:30:32,730
THOMAS: Clearly, they
knew it was a problem.
553
00:30:32,797 --> 00:30:35,066
NARRATOR: Boeing was so
concerned about the problem,
554
00:30:35,133 --> 00:30:36,668
it issued a special work order
555
00:30:36,734 --> 00:30:42,473
to secure the downstop
assembly on all 737s worldwide.
556
00:30:42,540 --> 00:30:45,610
RODNEY: The solution
that Boeing had recommended
557
00:30:45,677 --> 00:30:50,648
was to remove the nut
from this particular device
558
00:30:50,715 --> 00:30:54,886
and install some
thread hardening material,
559
00:30:54,953 --> 00:31:00,758
and then you reinstall
the nut. It hardens in place.
560
00:31:00,825 --> 00:31:02,493
THOMAS: What if the
work order on this plane
561
00:31:02,560 --> 00:31:04,195
was never completed?
562
00:31:04,262 --> 00:31:08,766
NARRATOR: Investigators
review the Boeing work orders.
563
00:31:08,833 --> 00:31:12,537
If the plane that burned
in Okinawa was never fixed,
564
00:31:12,604 --> 00:31:15,073
that could explain the accident.
565
00:31:15,139 --> 00:31:16,207
THOMAS: We tried to figure out
566
00:31:16,274 --> 00:31:21,846
when is the last time
anybody touched that assembly.
567
00:31:21,913 --> 00:31:23,748
NARRATOR: But
according to the records,
568
00:31:23,815 --> 00:31:27,418
the proper work was
carried out very recently.
569
00:31:27,485 --> 00:31:29,854
BOB: We discovered that
this particular component,
570
00:31:29,921 --> 00:31:32,123
this downstop,
had been manipulated
571
00:31:32,190 --> 00:31:35,293
only a couple of weeks or
so prior to the accident.
572
00:31:35,360 --> 00:31:37,962
THOMAS: It just
doesn't make sense.
573
00:31:38,029 --> 00:31:40,064
NARRATOR: Investigators
can see that the nut
574
00:31:40,131 --> 00:31:44,302
on the downstop
assembly is still attached.
575
00:31:44,369 --> 00:31:47,305
It seems that the work order
to replace it was completed
576
00:31:47,372 --> 00:31:52,677
just as the records
show. So what went wrong?
577
00:31:52,744 --> 00:31:55,813
THOMAS: That's the weird part
that we wanted to figure out
578
00:31:55,880 --> 00:31:58,349
at that time.
579
00:31:58,416 --> 00:32:02,487
NARRATOR:
They examine the downstop
assembly from Flight 120.
580
00:32:02,553 --> 00:32:05,189
♪
581
00:32:05,256 --> 00:32:09,927
They check all
the component parts.
582
00:32:09,994 --> 00:32:14,299
Finally, they spot something.
583
00:32:14,365 --> 00:32:17,335
BOB: We decided to count
parts, and lo and behold,
584
00:32:17,402 --> 00:32:20,505
a washer was missing.
585
00:32:20,571 --> 00:32:23,074
♪
586
00:32:23,141 --> 00:32:26,044
THOMAS: Where is it?
587
00:32:26,110 --> 00:32:29,514
NARRATOR: There's supposed to be
a washer right behind the nut.
588
00:32:29,580 --> 00:32:31,082
Could a single missing washer
589
00:32:31,149 --> 00:32:35,253
have played a role in the
accident? It seems unlikely.
590
00:32:35,320 --> 00:32:38,222
But investigators
can't rule it out.
591
00:32:38,289 --> 00:32:40,358
They need to find the washer.
592
00:32:40,425 --> 00:32:41,626
BOB: We thought
initially that the washer
593
00:32:41,693 --> 00:32:44,262
may have somehow
gotten inside the fuel tank,
594
00:32:44,329 --> 00:32:47,665
but that's not the case at all.
595
00:32:47,732 --> 00:32:51,769
We examined very
carefully the rest of the wing,
596
00:32:51,836 --> 00:32:53,604
and we found that
particular washer
597
00:32:53,671 --> 00:32:56,341
in the leading edge
assembly of the wing,
598
00:32:56,407 --> 00:32:58,343
just laying in there loose.
599
00:33:01,813 --> 00:33:03,781
THOMAS: The washer is a fit.
600
00:33:03,848 --> 00:33:05,249
NARRATOR:
Recovering the missing washer
601
00:33:05,316 --> 00:33:08,453
raises a puzzling question.
602
00:33:08,519 --> 00:33:11,255
BOB: The nut was on there and
it was torqued down correctly,
603
00:33:11,322 --> 00:33:14,826
but there was no
washer on it at all.
604
00:33:14,892 --> 00:33:17,662
How did the washer
become detached from the bolt
605
00:33:17,729 --> 00:33:19,297
but not the nut?
606
00:33:19,364 --> 00:33:21,599
THOMAS: If the nut
is still on the bolt,
607
00:33:21,666 --> 00:33:27,238
why is there something
between that fell off?
608
00:33:27,305 --> 00:33:29,173
NARRATOR: It seems
like an impossibility,
609
00:33:29,240 --> 00:33:31,743
and yet somehow it happened.
610
00:33:37,281 --> 00:33:40,985
The Flight 120 fire
investigation heads to Taiwan
611
00:33:41,052 --> 00:33:45,523
and the
headquarters of China Airlines.
612
00:33:45,590 --> 00:33:47,492
Investigators hope
to shed some light
613
00:33:47,558 --> 00:33:49,994
on the mystery of
the detached washer.
614
00:33:50,061 --> 00:33:53,998
THOMAS: I appreciate
you making the time.
615
00:33:54,065 --> 00:33:56,100
THOMAS: We went
to China Airlines
616
00:33:56,167 --> 00:34:01,406
to ask them to demonstrate how
they do the maintenance work.
617
00:34:01,472 --> 00:34:03,074
THOMAS: Do you think you
can show me how you completed
618
00:34:03,141 --> 00:34:06,577
this repair on the
downstop assembly?
619
00:34:06,644 --> 00:34:08,479
BOB: Sometimes maintenance
records don't tell you
620
00:34:08,546 --> 00:34:09,614
the true story.
621
00:34:09,680 --> 00:34:12,216
They can tell you that
according to somebody,
622
00:34:12,283 --> 00:34:15,119
a maintenance procedure
had been done correctly.
623
00:34:15,186 --> 00:34:16,354
But to get a better story,
624
00:34:16,421 --> 00:34:20,324
you have to actually
watch the procedure being done.
625
00:34:20,391 --> 00:34:21,292
NARRATOR: A
mechanic demonstrates
626
00:34:21,359 --> 00:34:26,898
how he performed
the downstop repair.
627
00:34:26,964 --> 00:34:32,870
MECHANIC: You won't be able
to see much of what I'm doing.
628
00:34:32,937 --> 00:34:36,507
RODNEY: Performing maintenance
on this particular downstop
629
00:34:36,574 --> 00:34:40,178
is a little tricky.
630
00:34:40,244 --> 00:34:45,383
The mechanic is going to be in
a very restricted visual area.
631
00:34:45,450 --> 00:34:48,119
So he's going to have
to work with his hands.
632
00:34:48,186 --> 00:34:53,958
He's going to have
to feel the apparatus.
633
00:34:54,025 --> 00:34:58,563
MECHANIC: After applying glue,
you put the bolt into place.
634
00:34:58,629 --> 00:35:00,565
♪
635
00:35:00,631 --> 00:35:03,668
THOMAS: You can imagine
that you're under the wing
636
00:35:03,734 --> 00:35:05,236
and you cannot see it.
637
00:35:17,515 --> 00:35:20,685
MECHANIC: Sorry. I just
dropped it. Don't worry.
638
00:35:20,751 --> 00:35:23,254
It's easy to pick up again.
639
00:35:31,462 --> 00:35:34,532
NARRATOR: It's an
eye-opening demonstration.
640
00:35:34,599 --> 00:35:36,601
MECHANIC: And
that's how it's done.
641
00:35:36,667 --> 00:35:39,570
THOMAS: Thank you. You
have been very helpful.
642
00:35:39,637 --> 00:35:42,607
THOMAS: It's not very
easy for them to confirm
643
00:35:42,673 --> 00:35:47,044
they finished their job and
everything is in order there.
644
00:35:47,111 --> 00:35:50,982
♪
645
00:35:51,048 --> 00:35:53,518
NARRATOR: Records show
that the work order repair
646
00:35:53,584 --> 00:35:56,621
was the only time mechanics
ever serviced the downstop
647
00:35:56,687 --> 00:36:00,992
in the history of
the accident airplane.
648
00:36:01,058 --> 00:36:02,960
There's only one
possible explanation
649
00:36:03,027 --> 00:36:08,065
for how the washer
found in Okinawa came loose.
650
00:36:08,132 --> 00:36:12,770
It fell off during the
maintenance procedure in Taiwan.
651
00:36:12,837 --> 00:36:15,106
BOB: It could have just slipped
off the gentleman's fingers
652
00:36:15,172 --> 00:36:19,810
when he was
trying to install it.
653
00:36:19,877 --> 00:36:22,179
It could have stuck to
the nut and then fallen off
654
00:36:22,246 --> 00:36:25,950
just before he
touched them together.
655
00:36:26,017 --> 00:36:27,585
A lot of things
could have happened.
656
00:36:27,652 --> 00:36:34,225
The bottom line is,
the washer was not there.
657
00:36:34,292 --> 00:36:40,531
♪
658
00:36:40,598 --> 00:36:42,867
NARRATOR: But understanding
what happened to the washer
659
00:36:42,934 --> 00:36:46,737
still leaves investigators
scratching their heads.
660
00:36:46,804 --> 00:36:49,473
The downstop assembly
had a well-tightened nut
661
00:36:49,540 --> 00:36:53,544
that was also glued to the
bolt. How could it fall out?
662
00:36:58,950 --> 00:37:01,752
And how did this piece
start a raging fuel fire
663
00:37:01,819 --> 00:37:04,221
that destroyed a
$70 million airplane
664
00:37:04,288 --> 00:37:07,291
and threatened the
lives of 165 people?
665
00:37:11,629 --> 00:37:12,897
♪
666
00:37:12,964 --> 00:37:18,269
THOMAS: All right. Now
let's test it without a washer.
667
00:37:18,336 --> 00:37:20,972
NARRATOR:
Investigators experiment
with the suspicious part
668
00:37:21,038 --> 00:37:24,976
from Flight 120 to see how
it performs without the washer.
669
00:37:25,042 --> 00:37:28,145
RODNEY: The design of this
assembly requires each component
670
00:37:28,212 --> 00:37:29,680
to play a specific role.
671
00:37:29,747 --> 00:37:37,221
So any piece that is not
reinstalled is critical.
672
00:37:37,288 --> 00:37:39,790
NARRATOR: They make
a stunning discovery.
673
00:37:44,528 --> 00:37:46,330
The small washer
is the only thing
674
00:37:46,397 --> 00:37:50,401
preventing the unit from
falling out of its mount.
675
00:37:50,468 --> 00:37:55,272
THOMAS: Without
the washer, it fails.
676
00:37:55,339 --> 00:37:57,141
BOB: We discovered
that the nut and the bolt
677
00:37:57,208 --> 00:37:59,810
were smaller than
the rest of the assembly
678
00:37:59,877 --> 00:38:06,550
and that the washer
was a required item.
679
00:38:06,617 --> 00:38:09,887
This is an example of an
intact downstop assembly.
680
00:38:09,954 --> 00:38:16,027
You take the nut off.
You take the washer off.
681
00:38:16,093 --> 00:38:20,164
Put the nut back on,
like they did in Taiwan,
682
00:38:20,231 --> 00:38:22,400
and now you'll note
that the assembly itself
683
00:38:22,466 --> 00:38:24,535
is pretty ineffective.
684
00:38:24,602 --> 00:38:30,207
It falls apart
without much problem at all.
685
00:38:30,274 --> 00:38:31,509
♪
686
00:38:31,575 --> 00:38:34,311
NARRATOR: Finally, it's
clear why the downstop assembly
687
00:38:34,378 --> 00:38:37,948
was able to fall
out of the slat track.
688
00:38:38,015 --> 00:38:39,717
How it punctured the fuel tank
689
00:38:39,784 --> 00:38:42,787
is the final
piece of the puzzle.
690
00:38:42,853 --> 00:38:44,021
But investigators believe
691
00:38:44,088 --> 00:38:48,959
the design of the slat mechanism
itself may hold the answer.
692
00:38:49,026 --> 00:38:51,128
RODNEY: When the engineers
are designing these aircraft,
693
00:38:51,195 --> 00:38:55,066
they take into consideration
maximum space utilization
694
00:38:55,132 --> 00:38:58,135
and for the design
of a leading edge slat
695
00:38:58,202 --> 00:39:00,938
they came up with
something called a can.
696
00:39:01,005 --> 00:39:03,407
NARRATOR: The slat can
is the area inside the wing
697
00:39:03,474 --> 00:39:06,410
that houses the moving track.
698
00:39:06,477 --> 00:39:11,916
RODNEY: The can is a void
that extends into the fuel tank
699
00:39:11,982 --> 00:39:15,686
and allows for the
device that operates the slat
700
00:39:15,753 --> 00:39:18,189
to move in and out.
701
00:39:18,255 --> 00:39:20,825
NARRATOR: The space
inside the slat can is tight,
702
00:39:20,891 --> 00:39:24,795
just big enough
for the sliding track.
703
00:39:24,862 --> 00:39:28,532
Any foreign metal object taking
up any space inside the can
704
00:39:28,599 --> 00:39:31,669
would be an
accident waiting to happen.
705
00:39:31,736 --> 00:39:34,138
BOB: It would
render the entire assembly
706
00:39:34,205 --> 00:39:37,575
not only
non-functional but dangerous.
707
00:39:44,882 --> 00:39:46,217
♪
708
00:39:46,283 --> 00:39:49,487
THOMAS: China
Airlines flight 1-2-0,
709
00:39:49,553 --> 00:39:54,425
157 passengers, eight crew.
710
00:39:54,492 --> 00:39:57,061
NARRATOR: Investigators
believe they finally understand
711
00:39:57,128 --> 00:40:00,498
the sequence of events that
led to a devastating fuel fire
712
00:40:00,564 --> 00:40:04,235
in Okinawa.
713
00:40:04,301 --> 00:40:07,138
♪
714
00:40:07,204 --> 00:40:09,673
It all begins weeks
before the accident
715
00:40:09,740 --> 00:40:14,145
with a botched repair
to a critical component.
716
00:40:15,880 --> 00:40:21,952
A single missing washer turns a
downstop into a hidden danger,
717
00:40:22,019 --> 00:40:25,523
a bolt that can work
its way loose over time.
718
00:40:27,057 --> 00:40:28,893
BOB:
Washers really aren't supposed
to hold things together,
719
00:40:28,959 --> 00:40:31,629
but this washer did
because of its design.
720
00:40:38,269 --> 00:40:41,105
NARRATOR: Six weeks
after the failed repair...
721
00:40:41,172 --> 00:40:43,274
CPT. YU:
Please give the flight
attendants your full cooperation
722
00:40:43,340 --> 00:40:45,643
as they prepare
the cabin for landing.
723
00:40:45,709 --> 00:40:48,846
NARRATOR: A routine descent into
Okinawa requires the pilots
724
00:40:48,913 --> 00:40:51,916
to deploy the flaps
and slats as usual.
725
00:40:55,920 --> 00:40:58,923
Inside one of the track
cans on the right wing,
726
00:40:58,989 --> 00:41:04,829
the loosened downstop
is just barely holding on.
727
00:41:04,895 --> 00:41:06,263
Touchdown is enough of a jolt
728
00:41:06,330 --> 00:41:11,135
to finally knock the
downstop out of its track.
729
00:41:11,202 --> 00:41:13,037
CPT. YU: Flaps up.
730
00:41:13,103 --> 00:41:15,272
NARRATOR: The
unsuspecting crew soon retracts
731
00:41:15,339 --> 00:41:17,808
the flaps and slats.
732
00:41:17,875 --> 00:41:20,511
The plane's powerful
hydraulics move the slat track
733
00:41:20,578 --> 00:41:26,183
back into the can. But now the
downstop bolt is in the way.
734
00:41:26,250 --> 00:41:28,819
The track pushes it to
the back of the can and then
735
00:41:28,886 --> 00:41:32,890
straight through, puncturing
the right wing fuel tank.
736
00:41:37,027 --> 00:41:42,299
THOMAS: A hole in the
fuel tank caused the leak.
737
00:41:42,366 --> 00:41:44,235
The plane would
have been carrying
738
00:41:44,301 --> 00:41:47,338
thousands of liters of fuel.
739
00:41:47,404 --> 00:41:49,740
NARRATOR: As the plane
taxis, the engine exhaust
740
00:41:49,807 --> 00:41:53,344
is powerful enough to
disperse the leaking fuel.
741
00:41:53,410 --> 00:41:57,214
It can't come in contact with
the hot tail pipe or brakes.
742
00:41:57,281 --> 00:42:00,751
CPT. YU:
After-landing checklist.
743
00:42:00,818 --> 00:42:04,188
NARRATOR: But once the pilots
park and shut down the engines,
744
00:42:04,255 --> 00:42:07,691
the situation instantly
becomes much more dangerous.
745
00:42:07,758 --> 00:42:09,293
FO. TSENG: Engine start levers.
746
00:42:09,360 --> 00:42:13,063
CPT. YU: Engine
start levers cut off.
747
00:42:13,130 --> 00:42:14,565
NARRATOR: The
leaking fuel starts dripping
748
00:42:14,632 --> 00:42:18,969
directly onto the
scorching-hot tail pipe.
749
00:42:19,036 --> 00:42:21,305
PASSENGERS:
750
00:42:21,372 --> 00:42:24,174
JIM: What is going on out there?
751
00:42:24,241 --> 00:42:27,211
NARRATOR: The leaking
jet fuel ignites on contact.
752
00:42:27,278 --> 00:42:30,014
KIT:
The speed of the development
of the fire is incredible.
753
00:42:30,080 --> 00:42:35,519
Obviously fuel burns very well,
and it goes up like a bomb.
754
00:42:35,586 --> 00:42:37,321
FLIGHT ATTENDANT:
Everybody remain calm.
755
00:42:37,388 --> 00:42:39,323
NARRATOR: The cabin
crew's professional conduct
756
00:42:39,390 --> 00:42:42,092
gets 157
passengers off the plane
757
00:42:42,159 --> 00:42:47,965
in just one
minute and 42 seconds.
758
00:42:48,032 --> 00:42:50,968
♪
759
00:42:51,035 --> 00:42:53,304
The Naha Airport
fire leads investigators
760
00:42:53,370 --> 00:42:57,207
to a striking realization.
761
00:42:57,274 --> 00:43:04,248
THOMAS:
The repair that was ordered
actually caused the fire.
762
00:43:04,315 --> 00:43:05,349
BOB: It was kind of ironic.
763
00:43:05,416 --> 00:43:08,185
The Taiwanese maintenance
procedure was to prevent
764
00:43:08,252 --> 00:43:11,889
an accident, and in essence
the procedure had a lot to do
765
00:43:11,956 --> 00:43:16,026
with why this
particular accident happened.
766
00:43:16,093 --> 00:43:18,963
KIT: It's a great study
in unintended consequences.
767
00:43:19,029 --> 00:43:21,465
We really were
trying to fix a problem.
768
00:43:21,532 --> 00:43:23,334
We really didn't anticipate that
769
00:43:23,400 --> 00:43:26,203
every time we handle a
maintenance piece like this
770
00:43:26,270 --> 00:43:30,107
there is a risk. And it bit us.
771
00:43:30,174 --> 00:43:32,643
NARRATOR: In the wake of
the Naha Airport inferno,
772
00:43:32,710 --> 00:43:34,778
aviation
authorities around the world
773
00:43:34,845 --> 00:43:38,716
order the inspection of
the entire fleet of 737s.
774
00:43:38,782 --> 00:43:42,753
In the US alone, 21 planes are
found to have the same defect,
775
00:43:42,820 --> 00:43:46,890
all of them at risk of a
catastrophic fuel leak and fire.
776
00:43:46,957 --> 00:43:48,692
Boeing takes immediate action.
777
00:43:48,759 --> 00:43:50,928
It redesigns the
downstop mechanism
778
00:43:50,995 --> 00:43:53,497
and ensures that the
improved part is installed
779
00:43:53,564 --> 00:43:55,599
on each and every plane.
780
00:43:55,666 --> 00:43:57,267
KIT: Boeing made
the changes necessary
781
00:43:57,334 --> 00:44:00,637
to ensure that the
accident didn't occur again.
782
00:44:00,704 --> 00:44:02,373
It took a little
time, as it normally does,
783
00:44:02,439 --> 00:44:04,408
to get to the
final resolution of it,
784
00:44:04,475 --> 00:44:05,943
but they did what
they needed to do.
785
00:44:06,010 --> 00:44:08,512
♪
63378
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