Preventing Engine Run-Up Incidents

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Alice CALMELS
Flight Safety Director - Accident/Incident Investigator

PREVENTING

ENGINE RUN-UP INCIDENTS

Several safety initiatives have been launched at international level to tackle safety challenges related to ground maintenance operations. ATR was informed in 2018 and 2019 of major ground incidents linked to engine run-up maintenance tests.

Fortunately, no fatalities were linked to these events, but major damage were reported, and 3 ATR aircraft were declared beyond economical repair (hull loss).

ICAO Annex 19 states that all involved organizations’ Safety Management Systems are to perform associated internal investigations in order to identify contributing factors and prevent further occurrence. In the reported incidents, training and adherence to job instruction cards procedures were identified as improvement axes.

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Develop internal practices  –  Adhere to these practices

Within the ATR AMM (Aircraft Maintenance Manual), 73 Maintenance Procedures request a low power engine run-up and 33 request a high power engine run-up (above flight idle). One main barrier to prevent engine run-up incidents is to strictly adhere to procedures. Every step of the procedure is important.

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Step 1 – Aircraft preparation starts with people briefing and review of the procedures. The tests are to be conducted in pre-identified dedicated areas that are free of obstacles, bright areas, knowing that the areas for engine start and for high power engine run-up might be different as the latter requires additional safety distances. These areas around the aircraft can be identified utilizing ground markings showing minimum distances. Aircraft should also be facing the wind, adequate chocks must be positioned and fire extinguishers must be available and reachable rapidly. Cockpit preparation is a key element. This includes for example seats’ adjustments to have feet well positioned on the brake pedals, and clear communication between the engineers. Lack of adherence to best practices during aircraft preparation is one of the most common safety escapes.

Step 2 – Engine Start. The starting sequence commences with a full engine fire systems test. Good knowledge of the engine limits/parameters, such as the ITT (Interstage Turbine Temperature) limits is recommended.

During the Step 3 – Engine run-up, the operating crew must always have one hand on the Power Levers, ready to reduce to ground idle at any time, and a good knowledge of expected engine and aircraft systems parameters values. An external visual reference point is to be taken and continuously monitored to detect any displacement of the aircraft.

If a Step 4 – Taxi is to be performed, note that the carbon brakes efficiency increases with temperature. The ground clearance is to be confirmed all along the taxi, ensuring a knowledge of airport charts and of tower communication.

Lastly, for Step 5 – Engine shut down, as a reminder, the last wet motoring is to be followed by a dry motoring to mitigate the risk of hot start and engine fire.

However, ATR recommends additional training and qualification (aircraft type-rated) of all engineers in charge of Engine Run-Up.

ATR proposes an engine run-up training course. For the theoretical session, this course is held in class whilst for the practical session it is run on a simulator. The simulator prepares engineers to possible issues they may face during the engine run up, on engines but also on aircraft systems.

Currently the regulation does not impose simulator sessions. However, this is considered as a valuable and good practice among the industry and is a recommendation from ATR.

ATR recommends each operator to develop internal standard operating procedures (SOP) for an engine run-up, including all the steps described above and in the AMM.

Maintenance Procedures references:

  • ATR-A-72-XX-XX-00ZZZ-133Z-A,
  • ATR-A-72-XX-XX-04ZZZ-133Z-A,
  • ATR-A-72-XX-XX-00ZZZ-340Z-A,
  • ATR-A-72-XX-XX-02ZZZ-340Z-A.

As in all aspects of flight operations, maintenance operations also require a level of situational awareness, good communication and human factors considerations. Best practices for engine run-up include the need for the test to be carried out with two engineers on board and one outside of the aircraft.

Training & Qualification enhancement

With regards to EASA regulations, the minimum needed to perform an engine ground run in terms of personnel qualification is a license holder (B1 or equivalent) to sign the job card afterwards.

 Recurrent training is a key axis for decreasing the number of engine run-up incidents.

ACalmels