StarHalo
Flashaholic
On July 29th 2011, an Egyptair 777-200 was doing their pre-flight check with 291 passengers on board, the causeway still attached, when a fire erupted in the cockpit; checks were proceeding normally and nominally when the first officer/co-pilot heard a pop and hiss sound to the right of his seat, and fire/smoke jetted out from under the right side console. The pilot immediately ordered the first officer out and fought the fire with a fire extinguisher, to no avail. The first officer notified the crew and emergency disembarkation was underway and complete in under five minutes. Fire trucks were on scene in three minutes and extinguished the fire quickly. Seven people total suffered minor smoke inhalation, no other injuries.
Synopsis of the investigation:
Now picture all of this happening at ~30,000 feet over the Indian Ocean; a flash fire limited to just the cockpit destroys the cockpit interior entirely while the flight is underway, possibly compounded by a hole burnt through the fuselage which has depressurized the cabin. What air there is to be used by any remaining crew would be employed trying to find a way to regain control of the plane, but that supply would last roughly less than half an hour, at which point there would be no survivors from depressurization. The plane would then theoretically hold its course waiting for the next control input until loss of fuel, when it would glide gradually to the sea.
Synopsis of the investigation:
The aircraft showed no defects that could have contributed to the accident. The investigation determined there were no fuel, hydraulic or oil lines near the cockpit area where the fire started. The investigation thus focussed on the crew oxygen system reasoning that the speed of the fire development required an accelerant.
The system's stainless steel supply tubes were found without any leakages, the stainless steel spring showed no evidence of arcing/electrical short circuit however most of the wiring was missing near the supply tube with evidence of melting.
The aircraft was found to differ from Boeing's design in that a clamp supporting the first officer's wiring to the oxygen mask light panel was missing. The wiring was not sleeved and a large loop of unsupported wire was found. The investigation determined that about 280 aircraft including all of Egyptair's Boeing 777s were delivered that way.
The flexible oxygen mask hoses were tested for conductivity, some of which were found not conductive with others found conductive.
It was found: "contact between aircraft wiring and oxygen system components may be possible if multiple wire clamps are missing or fractured or if wires are incorrectly installed."
A laboratory analysis concluded: "A short circuit from electrical wiring, which is supposed to be in contact with or routed near the stainless steel oxygen supply tubing, would be the most likely source to provide electrical energy to the spring. It is supposed that the stainless steel spring had been subjected to high energy level, which heated the internal spring until it became an ignition energy source, causing the flexible oxygen hose to ignite and sustain a fire. The time to failure, may took few seconds depending on the amount of energy supplied to the internal spring."
Now picture all of this happening at ~30,000 feet over the Indian Ocean; a flash fire limited to just the cockpit destroys the cockpit interior entirely while the flight is underway, possibly compounded by a hole burnt through the fuselage which has depressurized the cabin. What air there is to be used by any remaining crew would be employed trying to find a way to regain control of the plane, but that supply would last roughly less than half an hour, at which point there would be no survivors from depressurization. The plane would then theoretically hold its course waiting for the next control input until loss of fuel, when it would glide gradually to the sea.