Original subtitles

[ALARM RINGING]

Pilot: FIRE. MAIN DECK FORWARD.

Narrator: WHEN FIRE BREAKS OUT,

IT'S ONE OF AVIATION'S WORST NIGHTMARES.

Man: FIRE SCARES THE HECK OUT OF PILOTS.

Controller: PLANE ON FIRE, RUNWAY 24.

Narrator: IN MANCHESTER, 1985...

Pilot: A FIRE ON NUMBER ONE.

Narrator: ...A HOLIDAY FLIGHT BOUND FOR THE MEDITERRANEAN

FACES A RUNWAY DISASTER.

Man: THE CREW HAD BEEN AWARE THAT THEY HAD A FIRE,

BUT DIDN'T REALLY APPRECIATE AT THE TIME

THE SEVERITY OF THE FIRE.

Man: EVACUATE! EVACUATE!

Narrator: IN THE SKIES OVER SAUDI ARABIA...

Flight attendant: THERE'S SMOKE IN THE BACK, REAL BAD.

Narrator: ...A FLIGHT FULL OF PILGRIMS IS CONSUMED BY FLAMES.

Man: BY THIS TIME, IT'S PANDEMONIUM INSIDE THE CABIN.

Pilot: FIRE. MAIN DECK FORWARD.

Narrator: AFTER A UPS CARGO PLANE CRASHES IN DUBAI...

Man: OKAY, LET'S GET MOVING.

Narrator: ...LIVES DEPEND ON INVESTIGATORS

GETTING THE RIGHT ANSWERS.

Man: I WANT YOU TO SEARCH THIS ENTIRE GRID.

Narrator: WHAT CAUSED THESE FIRES?

Pilot: I'VE GOT NO OXYGEN!

Narrator: AND WHY WERE THEY SO DEADLY?

Man: HE CAN'T SEE HIS INSTRUMENTS,

DOESN'T KNOW WHERE HE IS IN RELATION TO THE GROUND

OR THE AIRPORT.

IT'S ABOUT AS BAD AS YOU CAN GET.

Flight attendant: LADIES AND GENTLEMEN,

WE ARE STARTING OUR APPROACH.

Pilot: WE LOST BOTH ENGINES!

Flight attendant: PUT THE MASK OVER YOUR NOSE.

EMERGENCY DESCENT.

Pilot: MAYDAY, MAYDAY!

Flight attendant: BRACE FOR IMPACT!

Controller: I THINK I LOST ONE.

Man: INVESTIGATION STARTING INTO THIS TRAGEDY...

Man: HE'S GONNA CRASH!

♪

Narrator: JEDDAH AIRPORT IN SAUDI ARABIA.

IT HAS A SPECIAL TERMINAL

BUILT EXCLUSIVELY FOR THE MILLIONS OF MUSLIMS

WHO MAKE THE JOURNEY FOR THE ANNUAL HAJJ.

NIGERIA AIRWAYS FLIGHT 2120

PREPARES TO TAKE A GROUP OF PILGRIMS HOME

TO SOKOTO, NIGERIA.

THE 247 PASSENGERS ARE ON BOARD A DC-8

OPERATED BY CANADIAN AIRLINE NATIONAIR.

Andrew McIntosh: NATIONAIR WAS

A SCRAPPY LITTLE START-UP AIRLINE

BASED IN MONTREAL,

AND IT STARTED BY TAKING PEOPLE ON VACATIONS

TO SUNNY DESTINATIONS DURING THE WINTER,

AND THEN IT HAD THIS VERY UNUSUAL

OFFSHORE CHARTER BUSINESS,

WHICH IS WHAT BROUGHT THEM TO JEDDAH AND SAUDI ARABIA.

Narrator: CAPTAIN WILLIAM ALLAN

IS A FORMER CANADIAN AIR FORCE PILOT.

HE HAS MORE THAN 20 YEARS OF FLYING EXPERIENCE.

FIRST OFFICER KENT DAVIDGE WILL BE AT THE CONTROLS TODAY.

Victor Fehr: I'LL TURN ON THE AIR CON.

Narrator: AND VICTOR FEHR IS THE FLIGHT ENGINEER.

ALSO ON BOARD IS LEAD MECHANIC JEAN-PAUL PHILIPPE

AND PROJECT MANAGER ALDO TETTAMANTI.

William Allan: STARTING FOUR.

Narrator: AT 8:26 A.M.,

IT'S ALREADY 86 DEGREES OUTSIDE.

TO GET TO ITS TAKEOFF POSITION, FLIGHT 2120

MUST TAXI THREE MILES ACROSS THE SPRAWLING AIRFIELD.

Allan: THAT'S A LONG WAY AROUND.

Controller: GOOD MORNING, NIGERIAN 2120.

CLEARED FOR TAKEOFF, UH, 3-4 LEFT.

Kent Davidge: ALL ENGINES.

Allan: OKAY. YOU HAVE CONTROL.

SET MAX THRUST.

McIntosh: SO EARLY IN THE TAKEOFF ROLL...

[POP]

THEY HEAR A LOUD SOUND IN THE COCKPIT.

Fehr: WHAT'S THAT?

Narrator: THE INSTRUMENTS SHOW NO INDICATION OF TROUBLE.

Allan: 80 KNOTS.

90 KNOTS NOW.

Davidge: 90 KNOTS. CHECK.

McIntosh: THEY CONTINUE TO ACCELERATE.

Controller: NIGERIAN 2120, AIRBORNE...

TWO-NINE.

Allan: POSITIVE RATE.

Davidge: GEAR UP.

Narrator: THEN, JUST MOMENTS AFTER TAKEOFF...

Fehr: WE'VE GOT FOUR LOW PRESSURE LIGHTS.

Allan: YEAH.

Davidge: WE'RE LOSING HYDRAULICS HERE.

Narrator: IN THE CABIN, THE FIRST SIGNS OF TROUBLE.

Flight attendant: SMOKE. I SMELL SMOKE.

Man: WHERE?

Flight attendant: BACK THERE.

Man: I'LL TAKE A LOOK.

Allan: OKAY, ONE-SIX-ZERO,

AND WE'RE LOSING OUR HYDRAULICS, SIR.

WE'RE GONNA NEED TO COME BACK TO JEDDAH TO LAND.

[COUGHING]

Flight attendant: THERE'S SMOKE IN THE BACK, REAL BAD.

Allan: YEAH, WE'RE HEADING BACK.

WE'VE GOT A HYDRAULIC PROBLEM, OKAY.

McIntosh: SO THIS IS THE FIRST INDICATION THAT THE PILOT HAS

OF ANYTHING GOING ON IN THE BACK OF THE PLANE.

NOW THEY HAVE TO GRAPPLE WITH THIS BLAZE THAT IS SPREADING

THROUGH THE REAR OF THE AIRCRAFT.

Allan: OKAY, LET'S GET SQUARED AWAY

AND SEE WHAT WE'VE GOT HERE, PLEASE.

Narrator: IN THE CABIN,

IT'S BECOMING ALMOST IMPOSSIBLE TO BREATHE,

AND JEDDAH IS STILL ALMOST 12 MILES AWAY.

Fehr: YOU'VE LOST ALL HYDRAULICS.

Davidge: DAMN IT! I'VE GOT NO AILERONS!

Narrator: NIGERIA AIRWAYS FLIGHT 2120

IS NOW AN INFERNO.

Allan: OKAY, HANG ON. I'VE GOT IT.

Narrator: THE CREW HAS MANAGED TO TURN THE CRIPPLED DC-8

BACK TO JEDDAH AIRPORT.

Allan: LET'S GET LINED UP BEFORE THINGS GET ANY WORSE.

OKAY, SO WE'RE AT 2,000 FEET NOW,

DECLARING AN EMERGENCY.

WE ARE HAVING FLIGHT CONTROL PROBLEMS.

Controller: UH, TURN LEFT RIGHT NOW

HEADING ZERO-EIGHT-ZERO.

EXPECT RUNWAY THREE-FOUR-LEFT.

[SHOUTING]

McIntosh: BY THIS TIME, IT'S PANDEMONIUM INSIDE THE CABIN.

[COUGHING]

PASSENGERS ARE BEING ENGULFED BY FLAMES

AND BODIES ARE STARTING TO FALL FROM THE AIRCRAFT FUSELAGE.

Davidge: THERE IT IS! IT'S TWO MILES OUT!

Allan: ALL RIGHT.

LET'S GET ON THE GROUND.

I'VE LOST ELEVATORS.

CHRIST, I HAVE NO CONTROL!

LANDING GEAR DOWN!

Pilot: SAUDI AIR 738.

NIGERIA AIRLINES IS DOWN JUST SHORT OF RUNWAY 3-4-CENTER.

Narrator: THE FIERY EXPLOSION

AND SUDDEN IMPACT WITH THE GROUND

HAS ALL BUT OBLITERATED FLIGHT 2120.

247 PASSENGERS AND 14 CREW ARE DEAD.

THIS IS THE WORST ACCIDENT EVER FOR A CANADIAN AIRLINE

AND THE DEADLIEST CRASH OF A DC-8 IN HISTORY.

ONE DAY AFTER THE CRASH,

A TEAM OF CANADIAN INVESTIGATORS ARRIVES IN JEDDAH.

Bill Taylor: HAS ANYTHING BEEN REMOVED?

Narrator: BILL TAYLOR

IS THE TRANSPORTATION SAFETY BOARD OF CANADA'S

TECHNICAL EXPERT.

Taylor: MY FIRST VIEW OF THE CRASH SITE

WAS ONE OF ASTONISHMENT, REALLY,

AT THE SPREAD OF THE DEBRIS,

THE SEVERITY OF THE BREAKUP.

THERE WAS VIRTUALLY NOTHING TO IDENTIFY IT AS AN AIRCRAFT.

Narrator: TAYLOR IS JOINED BY LEAD INVESTIGATOR RON COLEMAN.

Ron Coleman: WHEN YOU'RE DEALING WITH 247 PASSENGERS

AND 14 CREW ALL DEAD,

THAT GETS YOUR ATTENTION.

Narrator: EXAMINING THE REMAINS OF FLIGHT 2120'S LANDING GEAR,

INVESTIGATORS DISCOVER THAT ONE OF THE LEFT WHEEL RIMS

SHOWS CLEAR SIGNS OF SCRAPING ALONG THE RUNWAY.

[POP]

Coleman: YOU CAN IMAGINE THE KIND OF HEAT

THAT THAT WOULD GENERATE RUNNING ALONG THE RUNWAY,

SCRAPING OFF.

Narrator: WHILE INVESTIGATORS WONDER

IF THE SCRAPED WHEEL RIM

COULD HAVE SOMETHING TO DO WITH THE CRASH,

BILL TAYLOR MAKES A CHANCE DISCOVERY.

Taylor: I NOTICED A PIECE OF PAPER

BLOWING ACROSS THE SITE.

I PICKED IT UP, AND IT TURNED OUT TO BE

PART OF THE A-FLIGHT INSPECTION CHECKLIST,

AND IT WAS THE ACTUAL PAGE THAT RECORDED TIRE PRESSURES.

HEY.

Narrator: THE MAINTENANCE CHECKLIST

SHOWS THAT THE TIRES WERE INFLATED TO NORMAL PRESSURE.

BUT THERE ARE TWO DIFFERENT COLORS OF INK,

WITH A SECOND ENTRY WRITTEN OVER THE FIRST.

Coleman: THERE IS A LAW IN THE AVIATION INDUSTRY

THAT NO DOCUMENT SHALL BE ALTERED,

AND THIS ONE LOOKED SUSPECT.

Narrator: WHILE THE MAINTENANCE CHECKLIST

IS SENT TO THE ROYAL CANADIAN MOUNTED POLICE IN CANADA,

INVESTIGATORS IN JEDDAH TURN THEIR ATTENTION TO THE TIRES.

SOME INTRIGUING CLUES HAVE BEEN LEFT ON THE RUNWAY.

Taylor: SO THIS IS THE OUTER LEFT ONE.

WE SEE WHERE THE INBOARD FRONT TIRE OF THE LEFT LANDING GEAR

HAD LOST ITS TIRE.

IN OTHER WORDS, THE TIRE HAD BLOWN

AND THE WHEEL HAD COME DOWN ON, INTO CONTACT WITH THE RUNWAY.

Narrator: TAYLOR CONCLUDES

THAT THE AIRCRAFT BLEW TWO ADJACENT TIRES,

BOTH FROM THE LEFT MAIN LANDING GEAR.

[POP]

Allan: WHAT'S THAT?

Davidge: IT'S SORT OF A SHIMMY.

William Fowler: TIRE FAILURES AT THE TIME

WERE NOT AN UNCOMMON EVENT, NOR ARE THEY TODAY.

Davidge: GEAR UP.

Fowler: YOU CAN TAKE OFF SUCCESSFULLY,

CONTINUE EN ROUTE AND LAND AT DESTINATION

WITHOUT ADVERSE CONSEQUENCES.

Davidge: WE'RE LOSING HYDRAULICS HERE.

Narrator: BUT IS IT POSSIBLE THAT A BLOWN TIRE

LED TO AN INTENSE FIRE THAT TOOK DOWN A DC-8 IN 10 MINUTES?

AT THE ROYAL CANADIAN MOUNTED POLICE FORENSICS LAB,

TECHNICIANS ANALYZE THE NATIONAIR MAINTENANCE LOG.

TESTS REVEAL TWO LAYERS OF INK ON THE LOG ENTRIES.

McIntosh: THE READINGS FOR THE TIRE PRESSURE

WERE WRITTEN OVER,

AND THE ACTUAL READINGS THAT WERE UNDERNEATH

SHOWED 20 TO 30 PSI BELOW THE REQUIRED LEVELS

TO OPERATE THE PLANE AND TIRES SAFELY.

Narrator: TESTS CONFIRM THAT THE ENTRIES WERE FALSIFIED.

Coleman: TELL ME WHAT THE PLAN WAS FOR THE TIRES.

Narrator: INVESTIGATORS QUESTION MECHANICS AT JEDDAH.

THEY LEARN THAT FOUR DAYS BEFORE THE CRASH,

AT A STOP IN GHANA, AFRICA,

MECHANICS THERE WANTED TO CHANGE THE TIRES.

THE TREAD WAS BEGINNING TO WEAR, AND THE PRESSURE WAS LOW.

FOLLOWING THIS TRAIL...

Taylor: YOU'RE NOT GONNA BELIEVE WHAT I JUST FOUND.

Narrator: ...TAYLOR UNCOVERS EVIDENCE

THAT THE TIRE CHANGE WAS NEVER CARRIED OUT.

A FAX FROM THE NATIONAIR PROJECT MANAGER IN JEDDAH

ORDERED IT STOPPED SO THE PLANE COULD STAY ON SCHEDULE.

Man: FORGET IT. THEY WANT US TO GET GOING.

McIntosh: SO THE FAX CAME IN AND SAID STOP THE TIRE CHANGE,

WE'RE WAY BEHIND,

WE MAY LOSE THE CONTRACT,

LOAD EVERYBODY UP AND GET BACK.

Narrator: RATHER THAN TOP UP THE TIRES,

A MECHANIC ALTERS THE LOG

TO MAKE IT APPEAR LIKE THE AIR PRESSURE

MEETS SAFETY STANDARDS.

THIS WILL PROVE TO BE A DEADLY DECISION.

THE DC-8'S MAIN LANDING GEAR

CONSISTS OF A LEFT AND RIGHT BOGIE,

EACH WITH FOUR WHEELS.

UNIFORM TIRE PRESSURE IS IMPORTANT.

IT ENSURES THE WEIGHT OF THE PLANE

IS DISTRIBUTED EVENLY BETWEEN ALL EIGHT WHEELS.

Taylor: WHEN YOU HAVE AN UNDER-INFLATED TIRE,

THAT TOTAL WEIGHT THEN IS DISTRIBUTED

OVER THE REMAINING WHEELS.

IT WOULD BE FELT

ON THE AXLE-MATE OF THE LOW-PRESSURE TIRE.

Narrator: BEFORE IT CRASHED, CLAIMING 261 LIVES,

THE SAME PLANE TOOK OFF AND LANDED SEVEN TIMES

WITH THE UNDER-INFLATED TIRES.

SO WHY DID THE TIRES BLOW ON JULY 11th AT JEDDAH?

Taylor: HOW LONG IS THAT TAXIWAY, ANYWAY?

Narrator: INVESTIGATORS LOOK AT THE LENGTH OF THE TAXIWAY

AND THE SEARING TEMPERATURES ON THE GROUND.

Allan: IT'S A LONG WAY AROUND.

Coleman: THEY TAXIED FOR FIVE KILOMETERS.

THE TIRES MUST HAVE BEEN BURNING UP ON THE TARMAC.

Taylor: WHEN YOU GET OVER-DEFLECTION

OR EXCESSIVE BENDING IN THAT AREA,

IT GENERATES HEAT.

Allan: MAX THRUST.

Taylor: IF YOU GENERATED ENOUGH HEAT,

THE NYLON BEGINS TO MELT AND PULLS APART.

THE TIRE BLOWS.

[POP]

Fehr: WHAT'S THAT?

Narrator: FIRST, ONE TIRE BURSTS...

Allan: 90 KNOTS NOW.

Narrator: ...QUICKLY FOLLOWED BY A SECOND TIRE.

[POP]

THE WHEEL RIM HITS THE RUNWAY.

Larry Vance: AND WHEN THAT STARTED TO DRAG AND WEAR

DOWN THE RUNWAY,

IT GOT SUPER HOT.

SO AS SOON AS THIS AIRCRAFT TOOK OFF

AND THEY RETRACTED THE LANDING GEAR,

THERE WAS BASICALLY NO SURVIVING.

Davidge: GEAR UP.

Narrator: THE CREW TAKES THE FIRE WITH THEM INTO THE AIR.

Fowler: UNFORTUNATELY, THE DC-8 DID NOT HAVE

ANY HEAT OR FIRE INDICATION

TO TELL THE CREW THAT THEY HADA PROBLEM WITH THE LANDING GEAR,

THE WHEEL WELL AREA.

Allan: CHRIST, I HAVE NO CONTROL!

Coleman: IT'S ALL OVER TEN SECONDS AFTER THEY LIFT OFF.

Allan: LANDING GEAR DOWN!

Vance: I DON'T BELIEVE

THAT THE PEOPLE WHO WERE MAKING THE DECISIONS

HAD IN THEIR HEADS

THAT THIS WAS A HAZARDOUS THING THAT THEY WERE DOING.

Narrator: A NUMBER OF CRITICAL CHANGES

CAME ABOUT AFTER THIS ACCIDENT.

SMOKE, FIRE, AND TEMPERATURE SENSORS IN THE WHEEL WELLS

ARE NOW MANDATORY.

MOST CRITICALLY, CREWS ARE TRAINED

ON THE IMPORTANCE OF PROPERLY INFLATED TIRES.

Phil Derner: THERE'S A SAYING

THAT EVERY REGULATION IS WRITTEN IN BLOOD,

AND IT'S TRUE.

BUT THE LESSONS THAT WE GET FROM THESE ACCIDENTS

ARE OBVIOUSLY INCREDIBLY VALUABLE.

WE CAN LOOK AT ACCIDENTS FROM THE PAST

AND APPLY THEM TO VERY SPECIFIC CRASHES OF THE PRESENT

WHERE SURVIVABILITY RATES ARE INCREDIBLE,

SPECIFICALLY BECAUSE OF THOSE LESSONS FROM THE PAST.

Narrator: IT'S JUST BEFORE 6:00 IN THE MORNING

AT MANCHESTER AIRPORT IN NORTHERN ENGLAND.

BRITISH AIRTOURS FLIGHT 28

IS SCHEDULED TO TAKE 131 PASSENGERS

FROM MANCHESTER TO THE GREEK ISLAND OF CORFU.

LINDSAY DAVIES IS GOING TO GREECE WITH HER BOYFRIEND,

CHARLIE THICKSON.

Lindsay Davies: ALL RIGHT. LET'S GO.

WE'D BEEN GOING OUT WITH EACH OTHER FOR A YEAR,

AND THAT'S ONE OF THE REASONS WE WERE SO EXCITED ABOUT IT.

YOU KNOW, IT WAS OUR FIRST HOLIDAY TOGETHER.

Narrator: CAPTAIN PETER TERRINGTON

IS IN COMMAND.

FIRST OFFICER BRIAN LOVE IS BEING TRAINED BY TERRINGTON.

Controller: B-TOURS 28, YOU ARE CLEAR FOR TAKEOFF.

Narrator: THE BOEING 737

HAS 3,000 YARDS TO GET TO TAKEOFF SPEED.

Peter Terrington: 80 KNOTS.

Brian Love: CHECK.

[POP]

Terrington: STOP!

Narrator: CAPTAIN TERRINGTON THINKS A TIRE HAS BLOWN.

Terrington: THE IMMEDIATE REACTION WAS TO STOP.

WE WERE QUITE A FEW KNOTS BELOW OUR DECISION SPEED.

Lindsay: I JUST ASSUMED THAT MAYBE A TIRE HAD BURST,

SO I WASN'T REALLY ALARMED AT THAT POINT.

BUT THE SITUATION IS GETTING MUCH WORSE.

FLAMES ARE NOW ERUPTING

FROM THE BACK OF ONE OF THE PLANE'S ENGINES.

LET ME BY.

Purser: PLEASE, SIT DOWN.

Narrator: AND SMOKE IS DRIFTING INTO THE CABIN.

Terrington: STOPPING. 28 MIKE. WE'RE ABANDONING TAKEOFF.

[BEEPING]

IT LOOKS LIKE WE'VE GOT A FIRE ON NUMBER ONE.

Controller: PLANE ON FIRE, RUNWAY 24.

Narrator: CAPTAIN TERRINGTON HAS TO ACT FAST.

Terrington: EVACUATE TO THE STARBOARD SIDE, PLEASE.

Narrator: HE DECIDES TO PULL OFF THE RUNWAY.

Purser: EVACUATE! EVACUATE!

PLEASE STAY CALM AND DON'T PANIC.

Narrator: ON THE 737, THERE ARE FOUR CABIN DOORS.

THE PAIR IN BACK ARE COVERED IN FLAMES AND SMOKE,

LEAVING ONLY TWO FOR 137 PEOPLE.

NOW ONE OF THESE EXITS WON'T OPEN.

Lindsay: IT JUST SEEMED TO GO ON FOREVER

BEFORE THEY STARTED EVACUATING.

AND THAT'S WHEN I THOUGHT, I'M NOT GOING TO GET OFF.

IT'S GONNA BLOW UP WITH ALL OF US ON IT.

[SIRENS]

Narrator: PARKED ON THE TAXIWAY,

FLAMES ENGULF THE CABIN OF BRITISH AIRTOURS FLIGHT 28.

137 PEOPLE ARE DESPERATE TO ESCAPE.

Terrington: WE HAD AN EVACUATION CHECKLIST,

BUT IT WAS FOUR PAGES LONG,

AND THE LAST ITEM WAS TO GET THE PASSENGERS OFF.

[COUGHING]

Narrator: OUTSIDE, FIREFIGHTERS STRUGGLE TO CONTAIN THE BLAZE,

SPRAYING FOAM INTO THE CABIN.

Joanna Toff: WE WANTED TO START TO EVACUATE THE PASSENGERS,

BUT THERE WAS A BIT OF A BOTTLENECK

AND NOBODY WAS COMING FORWARD.

THE AISLE IS QUITE NARROW,

AND I COULD SEE THIS BOY

THAT WAS REALLY SORT OF PUSHED AGAINST THE WALL.

HE COULDN'T GET OUT, SO I PULLED HIM BY HIS T-SHIRT.

HE SORT OF TUMBLED FORWARD AND AFTER THAT,

EVERYBODY SORT OF JUST TUMBLED IN BEHIND HIM.

Flight attendant: ALL RIGHT, PROP THE DOORS OPEN

AND JUMP DOWN THE SLIDE.

Narrator: LINDSAY IS PUSHED TO THE FRONT...

Lindsay: SEE YOU OUT THERE.

Narrator: ...SEPARATED FROM HER BOYFRIEND, CHARLIE.

Purser: GO, GO, GO, GO!

Narrator: DOZENS OF PASSENGERS

HAVE MANAGED TO MAKE IT OFF THE PLANE.

BUT THERE ARE STILL MANY MORE PEOPLE INSIDE,

TRAPPED IN THE CRUSH.

Lindsay: ONE THING I DID SEE WHEN I LOOKED BACK

WAS PEOPLE GOING TO THE FRONT, TOWARDS THE FRONT OF THE PLANE,

PUSHING THE SEATS FORWARD AS THEY WENT ALONG.

Purser: GO, GO, GO, GO, GO!

Lindsay: EVERYBODY WAS SCREAMING AND PANICKING,

AND THAT'S WHEN I THOUGHT, PEOPLE ARE GONNA DIE IN THERE.

Terrington: OKAY, GO, BRIAN. GO, BRIAN.

Narrator: TO SAVE THEIR LIVES, THE CAPTAIN AND FIRST OFFICER

ARE COMPELLED TO ABANDON THE EVACUATION CHECKLIST.

Terrington: WE DID AS MANY ITEMS AS WE COULD,

AND THEN WE BOTH WENT OUT OF THE FLIGHT DECK WINDOW.

AND WHEN WE TURNED ROUND ON THE GROUND,

WE SAW A COMPLETE WRECK OF AN AIRCRAFT,

AND IT HAD HAPPENED IN A MATTER OF SECONDS.

IT WAS, UH, DREADFUL.

Narrator: IT TAKES 125 FIREFIGHTERS

MORE THAN TWO HOURS TO PUT OUT THE BLAZE.

54 PEOPLE PERISH, UNABLE TO ESCAPE THE INFERNO.

ANOTHER WOULD DIE IN THE HOSPITAL.

THE SCALE OF THE TRAGEDY

BRINGS BRITISH PRIME MINISTER MARGARET THATCHER

TO THE CRASH SITE.

Margaret Thatcher: WHEN WE GET A TERRIBLE AIR CRASH

OF THIS KIND,

EVERYONE IS APPALLED AND SHOCKED OF COURSE.

Narrator: SO, WHAT CAUSED THE FIRE?

AND HOW COULD IT KILL SO MANY PEOPLE

EVEN THOUGH THE PLANE WAS ON THE GROUND?

BRITAIN'S AIR ACCIDENTS INVESTIGATION BRANCH

SENDS A TEAM TO MANCHESTER.

STEPHEN MOSS WILL BE INSPECTING THE PLANE'S ENGINES.

Stephen Moss: THIS SHOULD NOT REALLY HAVE HAPPENED.

THE AIRCRAFT DIDN'T EVEN GET AIRBORNE,

IT DIDN'T RUN OFF THE RUNWAY,

AND YET STILL 55 PEOPLE WERE KILLED.

Narrator: CHRIS PROTHEROE WILL FOCUS ON THE FIRE.

Chris Protheroe: WE WERE AWARE FROM INITIAL REPORTS

THAT THE FIRE HAD ENTERED THE AIRCRAFT VERY RAPIDLY

AS THE AIRCRAFT CAME TO A HALT.

AND THAT WAS A FOCUS FOR ME.

Moss: WELL, THE FIRST THING WE NOTICED CLEARLY

WAS THE HOLE IN THE UNDERSIDE OF THE WING,

AND RIGHT NEXT TO IT

WAS A GAPING HOLE IN THE SIDE OF THE ENGINE.

Narrator: COULD THE TWO HOLES BE LINKED?

INVESTIGATORS LOOK FOR CLUES ON THE RUNWAY.

THEY FIND A LARGE PIECE OF DOME-SHAPED METAL

ALONG THE PLANE'S PATH.

STEPHEN MOSS CAN SEE IT'S FROM A PIECE OF THE ENGINE

CALLED A COMBUSTOR CAN.

Moss: IT LOOKED LIKE THERE'D BEEN A SEPARATION OF THE CAN

FROM THE FRONT END FROM THE BACK END.

Narrator: THE COMBUSTION CHAMBER OF THE 737'S JET ENGINES

CONTAIN NINE COMBUSTOR CANS.

IT'S WHERE FUEL AND AIR ARE MIXED AND IGNITED

TO CREATE THRUST.

MOSS SUSPECTS THE FRACTURED CAN SOMEHOW BLEW APART

AND DESTROYED THE PLANE'S LEFT ENGINE.

Moss: IT HAD STRUCK

AN UNDER-WING FUEL TANK ACCESS PANEL

AND PUT A SIZABLE HOLE IN THAT,

WHICH DIRECTLY LED TO THE RELEASE

OF A VAST QUANTITY OF FUEL.

Narrator: TO FIND OUT WHY THE COMBUSTOR CAN ERUPTED,

INVESTIGATORS STUDY THE PLANE'S MAINTENANCE LOG.

THEY DISCOVER THAT A YEAR AND A HALF EARLIER

MECHANICS HAD REPAIRED SMALL CRACKS

IN SOME OF THE COMBUSTOR CANS.

BUT ONE CRACK ON CAN NUMBER NINE WAS UNUSUALLY LONG.

Moss: THE OVERHAUL MANUAL DID NOT GIVE ANY LIMIT

ON THE LENGTH OF CRACK THAT COULD BE REPAIRED.

Narrator: MECHANICS WELD ALL THE CRACKS CLOSED,

INCLUDING THE LONG CRACK ON CAN NUMBER NINE.

AFTER THE COMBUSTOR CHAMBERS ARE REASSEMBLED

AND ATTACHED TO THE WINGS...

Terrington: 80 KNOTS.

Narrator: ...THE WELDS ARE INACCESSIBLE TO INSPECTORS.

[POP]

Terrington: STOP!

Moss: IF THE AIRLINE HAD INSPECTED THE CANS,

I THINK THERE IS NO DOUBT

THAT THEY WOULD HAVE SEEN THE PROBLEM.

Terrington: IT LOOKS LIKE WE'VE GOT A FIRE ON NUMBER ONE.

Narrator: INVESTIGATORS NOW KNOW

WHAT CAUSED THE MANCHESTER DISASTER.

THE WELDED CRACK IN COMBUSTOR CAN NUMBER NINE

TEARS APART AS FLIGHT 28 SPEEDS DOWN THE RUNWAY.

THE FRONT OF THE CAN SHOOTS OFF FROM THE ENGINE

AND TEARS A HOLE

IN THE UNDERSIDE OF THE LEFT WING FUEL TANK.

FUEL LEAKS ONTO THE DAMAGED ENGINE

AND EXPLODES INTO FLAMES.

[SIRENS]

NOW INVESTIGATORS WANT TO FIND OUT

HOW THE FIRE OUTSIDE THE PLANE

SPREAD SO QUICKLY INTO THE CABIN

AND CAUSED THE DEATHS OF 55 PEOPLE.

INVESTIGATORS ARE PUZZLED

BY THE DESTRUCTIVE SPEED OF THE FIRE

ON BRITISH AIRTOURS FLIGHT 28.

CHRIS PROTHEROE EXAMINES THE DATA

TO SEE IF WEATHER PLAYED ANY ROLE.

Protheroe: THE WIND WAS THE MAIN FACTOR

THAT DETERMINED THE SEVERITY OFTHE FIRE IN TERMS OF ITS ATTACK

ON THE OUTSIDE OF THE AIRCRAFT,

HOW RAPIDLY IT PENETRATED THE AIRCRAFT,

AND IT ALSO AFFECTED THE CONDITIONS INSIDE THE CABIN.

Terrington: STOP!

Narrator: BELIEVING HE HAD BLOWN A TIRE,

CAPTAIN TERRINGTON MAKES A FATEFUL DECISION.

Terrington: STOPPING. 28 MIKE. WE ARE ABANDONING TAKEOFF.

Narrator: HE TURNS OFF THE RUNWAY

AND INTO A CROSSWIND

FROM THE LEFT SIDE OF THE AIRCRAFT,

WHICH SWEEPS UP THE FIRE BURNING UNDER THE LEFT WING.

THE WIND WRAPS THE FIRE AROUND THE BACK OF THE PLANE

AND INTO THE CABIN.

[SIRENS]

INVESTIGATORS HAVE DISCOVERED THE CONDITIONS

THAT CAUSED THE FIRE TO PENETRATE THE CABIN.

NOW THEY MUST SOLVE THE BIGGEST MYSTERY.

WHY DID 55 PEOPLE DIE

AFTER THE PLANE HAD SAFELY ABORTED A TAKEOFF?

WAS THERE A PROBLEM WITH THE EVACUATION?

Purser: EVACUATE! EVACUATE!

PLEASE STAY CALM AND DON'T PANIC.

Narrator: A FULL BOEING 737 IS DESIGNED TO BE EVACUATED

IN LESS THAN TWO MINUTES.

BUT 90 SECONDS AFTER FLIGHT 28 CAME TO A STOP,

MOST OF THE PASSENGERS WERE STILL ON BOARD.

Edward Trimble: YOU CAN IMAGINE UNDER THESE CONDITIONS

THAT PEOPLE HAVE GOT TO GET AWAY FROM THE SMOKE,

AND THE PEOPLE DID THIS

BY BASICALLY CLAMBERING OVER THE SEATS

AND OTHER PEOPLE IN FRONT OF THEM.

Narrator: IN LESS THAN FIVE MINUTES,

WHAT SHOULD HAVE BEEN A SURVIVABLE ACCIDENT

TURNED DEADLY.

TO BETTER UNDERSTAND WHAT HAPPENED ON FLIGHT 28,

PSYCHOLOGIST HELEN MUIR IS BROUGHT INTO THE INVESTIGATION.

MUIR CONFIGURES A CABIN TO DUPLICATE A BOEING 737.

THEN, TO HAVE THE VOLUNTEERS ACT AS THOUGH THE PLANE'S ON FIRE,

SHE OFFERS MONEY TO THE FIRST ONES OFF.

Helen Muir: AND THAT PRODUCED BEHAVIOR

THAT WAS QUITE UNBELIEVABLE.

PEOPLE WENT OVER SEATS, THEY WENT ROUND EACH OTHER,

ALL SORTS OF THINGS.

AND INDEED, WHEN SURVIVORS FROM THE ACTUAL MANCHESTER ACCIDENT

CAME AND SAW THE VIDEOS,

THEY SAID, YEAH, THAT'S HOW IT WAS.

Narrator: THE STAMPEDE IS MADE WORSE

BY THE PLANE'S DESIGN.

PASSENGERS BECOME JAMMED IN THE BULKHEAD OPENING

SEPARATING THE MAIN CABIN FROM THE GALLEY.

THE BULKHEAD OPENING OF A BOEING 737

IS 22.5 INCHES WIDE,

JUST ENOUGH FOR ONE PERSON TO FIT THROUGH.

MUIR'S RESEARCH LEADS TO A BREAKTHROUGH.

Muir: WE SHOWED, THROUGH REPEAT TESTING,

THAT IF YOU CHANGED THE MINIMUM GAP

FROM 20 TO 30 INCHES,

YOU WOULD DRAMATICALLY IMPROVE THE SPEED AT WHICH

PEOPLE COULD GET OUT

AND YOU'D REDUCE THE LIKELIHOOD

OF PEOPLE FALLING AND SLIPPING AND SO ON.

Narrator: HELEN MUIR'S RESEARCH

PROMPTS MANUFACTURERS

TO REDESIGN CABINS TO MAKE THEM SAFER.

THAT INCLUDES INCREASING THE SPACE

BETWEEN THE BULKHEAD WALLS TO 30 INCHES

AND INTRODUCING STRIP LIGHTING

TO HELP GUIDE PASSENGERS TO EXITS

EVEN WHEN THEY'RE BLINDED BY SMOKE.

Firefighter: JUMP, JUMP, JUMP, JUMP, JUMP!

Narrator: THE SKIES ARE SAFER NOW

BECAUSE OF BRITISH AIRTOURS FLIGHT 28,

THOUGH THE LESSONS LEARNED HAVE COME AT A TERRIBLE COST,

EVEN FOR THE SURVIVORS

LIKE LINDSAY DAVIES AND HER BOYFRIEND, CHARLIE THICKSON.

Lindsay: THERE WAS NOTHING WRONG, REALLY,

WITH US, WE THOUGHT,

NOTHING PHYSICAL WRONG WITH US.

BUT OUR LIVES CHANGED, YOU KNOW,

JUST IN THOSE, IN THOSE FEW HOURS.

Narrator: ALL THESE INNOVATIONS HAVE MADE FLYING SAFER.

BUT SOMETIMES THE PROBLEM ISN'T THE CREW OR THE PLANE.

A BOEING 747 CARGO JET

CLIMBS OUT FROM DUBAI INTERNATIONAL AIRPORT

BOUND FOR COLOGNE, GERMANY.

Matthew Bell: AUTOPILOT ENGAGED.

Narrator: AFTER A ROUTINE TAKEOFF,

THE CREW OF UPS FLIGHT 6 SETTLES IN FOR A LONG NIGHT.

FIRST OFFICER MATTHEW BELL IS PILOTING THE PLANE.

HE'S BEEN WITH UPS FOR FOUR YEARS.

Doug Lampe: NICE FLYING, BY THE WAY.

YOU GOT A GOOD TOUCH ON THE CONTROLS.

Narrator: CAPTAIN DOUG LAMPE IS ALSO A SEASONED PRO.

HE'S BEEN WITH UPS FOR 15 YEARS

AND LOGGED MORE THAN 4,000 HOURS ON THE 747.

INSIDE THE CARGO PLANE'S MASSIVE HOLD

IS 228,000 POUNDS OF FREIGHT.

AS THE 747 CLIMBS, IT PASSES INTO BAHRAIN'S AIRSPACE.

Lampe: BAHRAIN, UPS 6 CLIMBING TO FLIGHT LEVEL 3-2-0.

Controller: THAT'LL BE FINE, UPS 6.

THIS IS BAHRAIN, AND YOU ARE IN RADAR CONTACT.

Narrator: AIR TRAFFIC CONTROLLER RICHARD PHILLIPS

IS RESPONSIBLE FOR THE PLANE

WHILE IT FLIES THROUGH BAHRAIN'S AIRSPACE.

21 MINUTES AFTER TAKEOFF, AT 31,000 FEET...

[ALARM RINGING]

Lampe: FIRE. MAIN DECK FORWARD.

Narrator: ...AN ALARM WARNS OF A FIRE IN THE CARGO HOLD.

Lampe: I'LL FLY THE AIRPLANE.

YOU RUN THE CHECKLIST.

Bell: OKAY.

UH, CHECKLIST FOR FIRE, MAIN DECK FORWARD.

LAND AT NEAREST AVAILABLE AIRFIELD.

Lampe: JUST GOT A FIRE INDICATION ON THE MAIN DECK.

I NEED TO LAND ASAP.

Phillips: DOHA IS AT YOUR TEN O'CLOCK AND A HUNDRED MILES.

IS THAT CLOSE ENOUGH?

Lampe: HOW ABOUT WE TURN AROUND AND GO BACK TO DUBAI?

I'D LIKE TO DECLARE AN EMERGENCY.

Narrator: CAPTAIN LAMPE DECIDES NOT TO LAND AT DOHA

AND TURNS THE PLANE BACK TO DUBAI, 25 MINUTES AWAY.

Phillips: ALL AVAILABLE ASSISTANCE REQUIRED AT DUBAI.

EMERGENCY DESCENT UNDERWAY.

Bell: BACK TWO AND THREE OFF.

Narrator: THE FIRST OFFICER

ACTIVATES THE FIRE SUPPRESSION SYSTEM

AND DEPRESSURIZES THE CARGO HOLD.

THIS SUCKS THE OXYGEN FROM THE HOLD

AND IS SUPPOSED TO STIFLE THE FLAMES.

Lampe: GET YOUR OXYGEN MASK ON.

Narrator: BUT IT DOESN'T WORK.

THEY GET ANOTHER WARNING LIGHT,

AND FIRE ALARMS SOUND

IN SEVERAL DIFFERENT AREAS OF THE CARGO HOLD.

[ALARM RINGING]

THE FLAMES ARE SPREADING FAST.

SMOKE PENETRATES THE COCKPIT.

John Cox: A COCKPIT FULL OF SMOKE

IS AN ABSOLUTELY TERRIFYING CONDITION.

Phillips: UPS 6, DESCEND AND MAINTAIN ONE-ZERO-THOUSAND,

YOUR DISCRETION.

[ALARM RINGING]

Narrator: AN ALREADY TERRIFYING SITUATION

IS ABOUT TO GET EVEN WORSE.

Lampe: I'VE GOT NO CONTROL OF THE AIRPLANE.

Bell: WHAT?

Lampe: I HAVE NO PITCH CONTROL OF THE AIRPLANE!

Bill English: PITCH CONTROL.

THAT'S NOSE UP, NOSE DOWN OF THE AIRPLANE.

IT'S CRITICAL TO AIRSPEED,

AND AS HE GETS CLOSE TO THE RUNWAY,

CRITICAL TO BEING ABLE TO LAND.

Narrator: UPS 6 IS STILL 22 MINUTES AWAY

FROM DUBAI INTERNATIONAL AIRPORT,

AND THE CREW IS BLINDED BY SMOKE IN THE COCKPIT.

Lampe: TRY AND GET DUBAI INTO THE COMPUTER.

Narrator: IF THEY CAN GET CLOSE ENOUGH TO THE RUNWAY

AND MAINTAIN THE CORRECT SPEED,

A HIGH-TECH GUIDANCE SYSTEM AT THE AIRPORT

MIGHT HELP GET THE PLANE TO THE GROUND.

THE INSTRUMENT LANDING SYSTEM,

OR ILS,

SENDS OUT RADIO SIGNALS FROM THE END OF THE RUNWAY.

IT CAN GUIDE THE PLANE DOWN VERTICALLY AND HORIZONTALLY

FROM ABOUT 12 MILES OUT.

Lampe: OKAY. UPS 6 IS STRAIGHT IN TO 12-LEFT.

Phillips: ALL PLANES STAND BY.

Narrator: BUT JUST WHEN THE CREW NEEDS HIM MOST,

PHILLIPS LOSES RADAR CONTACT.

Phillips: EMIRATES, THIS IS BAHRAIN AREA CONTROL.

I NEED YOUR READOUTS FOR UPS 6.

THEY'RE OFF MY RADAR.

Narrator: PHILLIPS ASKS THE CONTROLLERS IN ABU DHABI

TO TRACK THE PLANE ON THEIR RADAR

AND SEND HIM UPDATES.

Controller: HEADING 1-0-6.

Phillips: UPS 6, HEADING IS 1-0-6.

[COUGHING]

Narrator: MOMENTS LATER,

THE PILOTS FACE THEIR WORST CRISIS YET.

[COUGHING]

Lampe: I GOT NO OXYGEN.

Narrator: THE CAPTAIN NEEDS TO REACH

A SUPPLEMENTAL OXYGEN SUPPLY BEHIND HIM.

HE MUST HAND OVER COMMAND.

Lampe: YOU FLY.

Bell: I'VE GOT IT. I HAVE CONTROL.

Narrator: THE CAPTAIN DOESN'T MAKE IT.

Lampe: OXYGEN... [COUGHS]

Narrator: FIRST OFFICER BELL IS NOW ON HIS OWN.

Bell: MAYDAY, MAYDAY, MAYDAY!

CAN ANYONE HEAR ME?

Narrator: AND HE'S ALSO FACING ANOTHER CHALLENGE.

BELL IS ABOUT TO FLY OUT OF BAHRAIN'S RADIO RANGE.

Phillips: UPS 6, CONTACT DUBAI 1-3-2-DECIMAL... [STATIC]

Narrator: CONTROLLERS GIVE HIM A NEW FREQUENCY

TO TUNE IN TO DUBAI CONTROL.

BUT IT'S NO USE.

THE SMOKE IN THE COCKPIT IS TOO THICK.

Darren Straker: HE COULDN'T CHANGE BACK

TO THE DUBAI FREQUENCY,

SO THE PROBLEM NOW IS

HOW DO YOU TALK TO SOMEONE OUT OF RADIO RANGE

ON YOUR FREQUENCY?

Narrator: HIS ONLY CHOICE

IS TO STAY WITH PHILLIPS IN BAHRAIN.

Bell: CAN YOU GIVE ME AN ALTITUDE?

Narrator: PHILLIPS HAS TO THINK FAST.

HE SCRAMBLES TO FIND PLANES FLYING WITHIN RADIO RANGE

OF BOTH BAHRAIN CONTROL AND UPS 6.

Phillips: DUBAI 1, YOU'RE RADAR CONTACT, SIR.

I NEED YOU TO DO RELAYS FOR UPS 6.

Pilot: ALL RIGHT.

WHAT DO YOU WANT ME TO TELL UPS 6?

Phillips: I WANT YOU TO TELL HIM EXACTLY WHAT I SAY

WHEN I SAY IT.

Cox: THERE'S A LOT OF PEOPLE IN THIS COMMUNICATION LOOP,

AND INFORMATION HAS TO PASS

FROM ONE PERSON TO THE NEXT TO THE NEXT TO THE NEXT,

AND THIS TAKES TIME,

AND THAT'S SOMETHING THE FIRST OFFICER

DOESN'T HAVE VERY MUCH OF.

Narrator: AS HE NEARS THE AIRPORT,

BELL STRUGGLES TO LOCK ON TO THE RUNWAY SIGNAL.

HE PUSHES THE ILS APPROACH BUTTON.

Bell: COME ON!

Controller: HE'S TOO HIGH, AND HE'S TOO FAST!

Narrator: BELL IS OVERSHOOTING THE RUNWAY.

Phillips: IS HE ABLE TO MAKE A LEFT TURN

FOR A TEN-MILE FINAL FOR SHARJAH?

English: AIR TRAFFIC THOUGHT QUICK.

THEY KNEW THERE WAS ANOTHER RUNWAY NEARBY

AND TRIED TO GIVE HIM GUIDANCE TO MAKE THAT RUNWAY.

Pilot: ARE YOU ABLE TO MAKE A LEFT TURN NOW TO SHARJAH?

IT'S TEN MILES AWAY.

HEADING 0-9-5.

Narrator: BELL TRIES TO ENTER THE HEADING

INTO THE AUTOPILOT.

Controller: HE'S MADE A RIGHT TURN.

A RIGHT TURN!

English: UNFORTUNATELY, ONE DIGIT WAS WRONG, 1-9-5,

AND INSTEAD OF TURNING LEFT TOWARD SHARJAH,

THE AIRPLANE TURNED RIGHT,

AWAY FROM DUBAI AND SHARJAH.

Narrator: BELL REALIZES THE PLANE

IS BANKING THE WRONG WAY.

HE DISCONNECTS THE AUTOPILOT TO TRY TO CORRECT HIS COURSE.

Bell: MY AIRSPEED!

Pilot: WHAT'S HIS AIRSPEED?

Phillips: GROUND SPEED 2-6-6.

Cox: THE FIRST OFFICER NEVER GAVE UP

TRYING TO FLY THE AIRPLANE OR LAND THE AIRPLANE.

Computer: TERRAIN. PULL UP.

Bell: AAGGH!

Pilot: WHAT'S THE WORD?

Phillips: RADAR CONTACT LOST.

Narrator: UPS 6 HAS CRASHED INTO A MILITARY BASE

TEN MILES FROM DUBAI INTERNATIONAL AIRPORT.

NEITHER PILOT HAS SURVIVED.

FORTUNATELY, THERE ARE NO FATALITIES ON THE GROUND.

THE $220 MILLION PLANE IS NOW CHARRED RUBBLE,

SPREAD OVER A WRECKAGE SITE THE SIZE OF SIX FOOTBALL FIELDS.

Cox: THE AIRPLANE HAD HIT AT VERY HIGH SPEED.

THERE WERE A LOT OF SMALL PIECES,

AND WHEN THAT HAPPENS, FROM AN INVESTIGATIVE STANDPOINT,

IT'S GOING TO BE REALLY CHALLENGING.

Narrator: THE UNITED ARAB EMIRATES

AIR ACCIDENT INVESTIGATION UNIT

APPOINTS DARREN STRAKER TO LEAD THE INVESTIGATION.

Straker: OKAY. LET'S GET MOVING.

WE NEED TO SEE EVERY PIECE.

THE FIRST QUESTION IS WHAT WAS ON FIRE?

HOW DID IT GET ON BOARD?

AND HOW DID THIS 747 DROP OUT OF THE SKY?

Narrator: SINCE THE 747 IS AMERICAN BUILT...

English: WHAT DO YOU NEED?

Narrator: ...BILL ENGLISH

FROM THE U.S. NATIONAL TRANSPORTATION SAFETY BOARD

JOINS THE TEAM.

English: FIRST THINGS TO LOOK FOR

WERE THE FLIGHT RECORDERS,

THE CVR AND FDR.

Narrator: THE COCKPIT VOICE RECORDER

IS FOUND ALMOST IMMEDIATELY.

Lampe: I'LL FLY THE AIRPLANE, YOU RUN THE CHECKLIST.

Bell: OKAY.

Narrator: THE RECORDING SHOWS THE CREW REACTED QUICKLY...

Bell: BACK TWO AND THREE OFF.

Narrator: ...ENGAGING THE ONBOARD SYSTEMS

DESIGNED TO CONTAIN A FIRE.

WHY COULDN'T THEY MAKE IT BACK TO THE AIRPORT?

Lampe: THIS IS UPS 6.

I NEED AN EMERGENCY DESCENT.

Straker: THE THING THAT STOOD OUT FOR ME

WAS THE SPEED OF THE ONSET OF THE PROBLEMS THEY FACED.

Lampe: TRY AND GET DUBAI INTO THE COMPUTER.

Straker: HOW DOES A FIRE GET SO OUT OF CONTROL

THAT THE AIRPLANE IS RENDERED ALMOST UNFLYABLE?

Narrator: THREE DAYS INTO THE GRID SEARCH

OF THE CRASH SITE OF UPS 6,

THE FLIGHT DATA RECORDER IS FOUND,

ALONG WITH AN UNEXPECTED CLUE.

English: INSIDE THAT BUSH

WAS ONE SMALL LITHIUM BATTERY THAT HAD BURNED,

BLOWN ITSELF UP,

AND SHOT OUT OF THE WRECKAGE INTO THE LITTLE BUSH.

Narrator: THE SMALL PIECE OF EVIDENCE

MIGHT JUST LEAD INVESTIGATORS

TO THE MYSTERIOUS CAUSE OF THE FIRE.

INVESTIGATORS LOOK AT THE 747'S CARGO.

Straker: PHEW!

81,000 BATTERIES.

THAT'S A LOT OF HAZARDOUS CARGO.

Narrator: THE CARGO MANIFEST REVEALS

UPS 6 HAD DOZENS OF SHIPMENTS OF LITHIUM BATTERIES

OR CONSUMER ELECTRONICS THAT CONTAIN THEM.

Straker: ONCE WE'D GOT THE CARGO MANIFEST

AND SEEN THE TOTAL VOLUME

OF THESE BATTERIES THAT WERE ON BOARD,

WE WERE HEADING IN THE RIGHT DIRECTION.

Narrator: LITHIUM BATTERIES

CAN PROVIDE UP TO TEN TIMES THE ENERGY

OF REGULAR ALKALINE BATTERIES.

BUT THEY ARE EXTREMELY FLAMMABLE.

THEIR VOLATILE CHEMICAL COMPOSITION

MEANS THEY CAN BURST INTO FLAMES IF THEY BECOME COMPROMISED.

IS THAT WHAT HAPPENED

IN THE CARGO HOLD OF UPS FLIGHT 6?

[ALARM RINGING]

AT A FACILITY IN THE UNITED STATES,

STRAKER PUTS THESE BATTERIES TO THE TEST.

THE RESULTS ARE ASTONISHING.

WHEN THEY HEAT A SINGLE BOX CONTAINING 100 BATTERIES,

IT QUICKLY IGNITES,

SENDING UP FLAMES THAT REACH TEMPERATURES

OF 2,000 DEGREES FAHRENHEIT.

Straker: WE WERE COMPLETELY SURPRISED

AT HOW A SMALL DOUBLE-A SIZE LITHIUM BATTERY WOULD OVERHEAT

AND THEN VENT

AND PRACTICALLY JUST EXPLODE INTO A PROBLEM

WHICH YOU COULDN'T CONTAIN.

Narrator: WITH THIS IN MIND,

INVESTIGATORS USE THE FLIGHT DATA RECORDER

TO MAP WHAT HAPPENED DURING THE FLIGHT OF UPS 6.

THEY'RE UNCLEAR AS TO WHY THE BATTERIES AUTO-IGNITED,

BUT THE FIRE DOES START

IN THE CARGO HOLD BENEATH THE COCKPIT.

Straker: BINGO.

English: IF YOU ARE FAMILIAR WITH THE 747,

YOU KNOW IT HAS THAT VERY DISTINCTIVE HUMP

UP IN THE FRONT.

THE COCKPIT IS PART OF THAT HUMP,

AND THE CARGO DECK IS UNDERNEATH THERE.

WE FOUND SOME SHIPMENTS IN THERE OF SOME PRETTY LARGE BATTERIES,

A LOT OF ENERGY PACKED IN A VERY DENSE PLACE.

English: ALL THE FAILURES WERE RIGHT HERE,

BEHIND THE COCKPIT.

Narrator: IN THE CROWDED CARGO DECK,

FLAMES SOON SPREAD TO OTHER CONTAINERS,

MANY OF THEM LOADED WITH BATTERIES.

[ALARM RINGING]

Lampe: FIRE. MAIN DECK FORWARD.

Narrator: BY THE TIME THE CREW GETS A WARNING,

THE FIRE IS RAGING TOO INTENSELY

FOR THE SUPPRESSION SYSTEM TO PUT IT OUT.

FIRE DESTROYS MORE SYSTEMS,

INCLUDING THE CAPTAIN'S OXYGEN SUPPLY

AND THE LANDING GEAR CONTROLS.

Bell: I HAVE NO GEAR!

Narrator: INVESTIGATORS BELIEVE

THE TRAGEDY WOULD HAVE BEEN EVEN WORSE

IF NOT FOR THE FINAL ACTIONS OF THE FIRST OFFICER.

AT THE LAST MOMENT,

IN A PLANE HE COULD BARELY CONTROL...

Phillips: IF ABLE, CLIMB IMMEDIATELY.

CLIMB IMMEDIATELY!

Narrator: ...HE MANAGES TO AVOID CRASHING

INTO A RESIDENTIAL SUBURB OF DUBAI.

Computer: PULL UP.

Narrator: THE FINAL REPORT URGES BETTER SMOKE DETECTORS

AND FIRE EXTINGUISHERS IN CARGO HOLDS,

AND IT CALLS FOR SAFER CONTAINERS.

IN RESPONSE, UPS IMPLEMENTS ITS OWN STATE-OF-THE-ART CONTAINERS

THAT SET A NEW STANDARD FOR FIRE RESISTANCE.

THE COMPANY ALSO DESIGNS FULL-FACE OXYGEN MASKS

FOR COCKPIT CREW

AND A SEALED AIR SYSTEM

THAT PREVENTS SMOKE FROM OBSCURING THE INSTRUMENTS

AND WINDSHIELD.

THE TRAGEDIES EXPERIENCED AT DUBAI, JEDDAH, AND MANCHESTER

EXACTED A TERRIBLE HUMAN COST.

BUT THEY HAVE ALSO HELPED LEAD THE WAY

TOWARDS SKIES THAT HAVE NEVER BEEN SAFER.

Derner: WE'VE KIND OF REACHED THIS PINNACLE

IN AVIATION SAFETY THESE DAYS.

BUT WE WERE ABLE TO TAKE ALL OF THOSE ACCIDENTS,

LEARN THOSE LESSONS, APPLY THEM,

AND MAKE IT THAT MUCH SAFER.

AND WE ARE LIVING IN THIS ERA, THIS REMARKABLE ERA RIGHT NOW

BECAUSE OF THAT,

BECAUSE THEY DID NOT DIE IN VAIN.