Incident: Faulty Propeller Barrels Ground US Air Force C-130H Planes

Published Date: 2022-09-30

Postmortem Analysis
Timeline 1. The software failure incident involving the grounding of more than 100 C-130H cargo planes due to faulty propeller barrels did not happen. This was a case of faulty propeller barrels causing the grounding of the planes, not a software failure incident.
System unknown
Responsible Organization unknown
Impacted Organization 1. The United States Air Force Reserves 2. The Air National Guard [Cited from Article 132263]
Software Causes unknown
Non-software Causes 1. Faulty propeller barrels that could crack and leak fluid were identified as the main cause of the failure incident [132263]. 2. The issue was discovered during a maintenance check at the Warner Robins Air Logistics Complex in Georgia, where a persistent leak was found in a C-130 H propeller during engine testing after maintenance [132263]. 3. The propeller assembly was then removed and sent to a propeller shop, where a crack in its barrel assembly was identified, leading to further inspections and the discovery of similar problems in two more propeller assemblies [132263]. 4. The grounding of the C-130H cargo planes was also linked to concerns about the propeller system, as similar issues had led to the grounding of 60 C-130Hs in 2019 due to fears of propeller blade cracks [132263].
Impacts unknown
Preventions 1. Implementing more rigorous quality control measures during the manufacturing process of the propeller barrels could have prevented the software failure incident [132263]. 2. Conducting more frequent and thorough inspections of the propeller assemblies for potential defects could have helped identify the issue earlier and prevent widespread grounding of the C-130H cargo planes [132263]. 3. Investing in advanced technology and materials for propeller manufacturing to ensure higher durability and reliability of the propeller barrels could have prevented the recurring issues with the propeller system [132263].
Fixes 1. Immediate replacement of the faulty propeller barrels on the affected C-130H cargo planes and their variants [132263]. 2. Conducting metallurgical reviews and stress analyses on the propeller assemblies to identify any cracks or defects [132263]. 3. Upgrading the propeller assemblies with the eight-bladed NP 2000 system to prevent future occurrences of the defect [132263].
References 1. Air Force Mobility Command confirmed to Defense News about the grounding of the C-130 Hercules cargo planes [132263]. 2. Unofficial Air Force amn/nco/snco Facebook page provided information about the affected aircraft and propeller barrels [132263]. 3. Maintenance crew at the Warner Robins Air Logistics Complex in Georgia discovered the persistent leak and crack in the propeller assembly [132263]. 4. The Air Force Times reported on the investigation findings of the crash involving a KC-130T in 2017 [132263].

Software Taxonomy of Faults

Category Option Rationale
Recurring unknown The articles do not mention any software failure incidents related to the United States Air Force or any other organization. Therefore, the information about the software failure incident happening again at one organization or multiple organizations is unknown.
Phase (Design/Operation) design Unknown
Boundary (Internal/External) within_system The software failure incident reported in the provided article [132263] is related to the propeller barrels of the C-130 Hercules cargo planes. This incident falls under the category of within_system failure as it was caused by a fault within the propeller barrels themselves. The issue was specifically related to the propeller barrels being faulty, with cracks that could lead to leaks, affecting the functionality of the planes. The failure originated from within the system components, leading to the grounding of more than 100 cargo planes for inspection and replacement of the affected propeller barrels.
Nature (Human/Non-human) non-human_actions (a) The software failure incident in this case is not related to non-human actions but rather to a mechanical issue with faulty propeller barrels that could crack and leak fluid, leading to the grounding of more than 100 C-130 Hercules cargo planes [132263]. (b) The failure in this incident is attributed to a mechanical issue with the propeller barrels that were found to have cracks, leading to the grounding of the planes. This issue was discovered during maintenance checks when a persistent leak was observed from a C-130 H propeller, prompting further inspections that revealed cracks in the barrel assembly. The decision to ground the planes and investigate the extent of the issue was made by the Air Force Mobility Command [132263].
Dimension (Hardware/Software) hardware (a) The software failure incident occurring due to hardware: The reported incident of the United States Air Force grounding more than 100 cargo planes was not directly related to a software failure incident originating from hardware issues. The grounding was due to concerns about faulty propeller barrels that could crack and leak fluid, which is a hardware issue related to the propeller assemblies on the C-130 Hercules cargo planes [132263]. (b) The software failure incident occurring due to software: There was no mention of a software failure incident in the articles related to the grounding of the cargo planes. The primary reason for the grounding was the discovery of faulty propeller barrels that needed replacement, indicating a hardware issue rather than a software-related failure [132263].
Objective (Malicious/Non-malicious) non-malicious The software failure incident reported in the provided article [132263] is related to a non-malicious factor, specifically a technical fault in the propeller barrels of the C-130 Hercules cargo planes. The issue was identified as faulty propeller barrels that could crack and leak fluid, leading to the grounding of more than 100 cargo planes. The failure was attributed to a manufacturing defect in the propeller barrels, which necessitated immediate inspections and replacement of the affected components. This incident does not indicate any malicious intent but rather highlights a technical flaw in the equipment. Additionally, the article mentions a previous incident in February 2019 where 60 C-130Hs were grounded due to concerns about pre-1971 propeller blades cracking. This incident was also non-malicious and stemmed from a technical issue with the propeller blades, leading to a review of the propeller blade overhaul process to prevent similar failures in the future.
Intent (Poor/Accidental Decisions) unknown The articles do not mention any software failure incident related to poor decisions or accidental decisions.
Capability (Incompetence/Accidental) unknown The articles do not mention any software failure incident related to development incompetence or accidental factors. Therefore, the information regarding the software failure incident in relation to these factors is unknown.
Duration temporary The software failure incident related to the faulty propeller barrels affecting the C-130 Hercules cargo planes is a temporary failure. The incident led to the grounding of more than 100 C-130H planes due to concerns about cracks and leaks in the propeller barrels. The Air Force initiated immediate inspections, metallurgical reviews, and stress analyses to identify affected planes and ordered the replacement of the propellers. It is mentioned that newer C-130Js and C-130Hs with upgraded propeller assemblies are not affected by the defect. The timeline for replacing all affected propeller barrels has not been specified yet [132263].
Behaviour unknown (a) crash: The software failure incident in this case does not involve a crash of the system itself. The issue reported is related to faulty propeller barrels on C-130 Hercules cargo planes, leading to their grounding [132263]. (b) omission: There is no indication in the articles that the software system omitted to perform its intended functions at any instance. (c) timing: The software system is not mentioned to have performed its intended functions too late or too early. (d) value: The software system is not reported to have performed its intended functions incorrectly. (e) byzantine: The software system is not described as behaving erroneously with inconsistent responses and interactions. (f) other: The software system is not described as exhibiting any other specific behavior not covered by the options provided.

IoT System Layer

Layer Option Rationale
Perception None None
Communication None None
Application None None

Other Details

Category Option Rationale
Consequence death, harm (a) death: People lost their lives due to the software failure - In a previous incident in 2017, a KC-130T crashed, resulting in the death of 15 Marines and a sailor. The crash was caused by a deteriorating propeller blade, which was already corroded when the plane entered an Air Force maintenance depot in 2011. The corrosion eventually deteriorated into a crack, leading to the crash and loss of lives [Article 132263].
Domain transportation, government <Article 132263> The software failure incident reported in the article is related to the transportation industry. The United States Air Force had to ground more than 100 cargo planes, specifically C-130 Hercules planes, due to concerns about faulty propeller barrels that could crack and leak fluid. This incident directly impacts the operations of the Air Force Reserves and the Air National Guard, which are essential components of the transportation sector, particularly in terms of military logistics and mobility [132263].

Sources

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