Luftwaffe VVIP Global 5000 Written Off After Flying Control Assembly Error
On 16 April 2019 Luftwaffe VVIP Bombardier BD-700-1A11 Global 5000 14+01 departed Berlin-Schönefeld (BER) for Cologne-Bonn (CGN) on its first flight after having undergone heavy maintenance by Lufthansa Bombardier Aviation Services (LBAS).
The aircraft climbed to c 21000 ft but suffered flight control problems. The aircraft returned to Berlin-Schönefeld but suffered severe roll instability and the both wing tips reportedly struck the runway. Some reports suggest the aircraft was exposed to 5g manoeuvres. The aircraft has now been assessed as write off due to the damage sustained.
In December 2019 the Luftwaffe said that:
As part of the work, a component of the flight control system was replaced. An error in the setting of so-called signal transducers in conjunction with a lack of care in the function verification resulted in a malfunction in the flight control.
Other reports suggest a torque tube assembly was misassembled.
The official military investigation report does not appear to have been made public. If more details emerge we will add to this article.
UPDATE 9 October 2020: Transport Canada have issued Airworthiness Directive CF-2020-35: Flight Controls – Roll Control Input-Modules (RCIMs) Incorrect Installation which states:
There are several in-service reports of a single RCIM being installed incorrectly, and one report of both RCIMs being installed incorrectly. An investigation has determined that it is physically possible for an RCIM to be installed and zeroed 180 degrees from its intended (design) installation orientation. If both RCIMs are installed incorrectly in the same manner, a misrigging condition occurs causing the multi-function spoilers (MFSs) to deploy opposite to the roll command. Misrigging of the MFS in this manner could lead to loss of control of the aeroplane.
To reduce the likelihood of incorrect RCIM installation during maintenance, the Aircraft Maintenance Manual (AMM) has been revised with improved RCIM installation and adjustment tasks. These improved tasks provide additional guidance to ensure proper orientation of the RCIM. A new AMM functional test task was introduced to improve the robustness of post-maintenance checks to confirm proper installation of the RCIMs. This AD requires the use of these latest AMM procedures when performing maintenance involving one or both RCIMs.
It is not clear if this AD is relevant to the Berlin-Schönefeld incident.
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FSF Maintenance Observation Programme (MOP)
Aerossurance worked with the Flight Safety Foundation (FSF) to create a Maintenance Observation Program (MOP) requirement for their contractible BARSOHO offshore helicopter Safety Performance Requirements to help learning about routine maintenance and then to initiate safety improvements:
Aerossurance can provide practice guidance and specialist support to successfully implement a MOP.