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Manufacturer test procedures
Date issue released
Safety Issue Description

The balloon manufacturer did not have an adequate process to verify the accuracy of the temperature recorded during production inflation tests.

Issue number
AO-2022-028-SI-01
Issue Status
Closed – Adequately addressed
Transport Function
Aviation: Air transport
Issue Owner
Kubicek Balloons
Mode of Transport
Aviation
Issue Status Justification

The updated production test procedure includes a more comprehensive test for balloons with modified deflation systems, which includes redundant temperature sensors and guidance on correct sensor installation. In addition, all standard balloons no longer use temperature sensors for the test, being replaced by a specific weight to be lifted which will ensure greater consistency in the internal envelope pressure during the test independent of ambient conditions. These changes adequately address the safety issue.

Proactive action
Action number
AO-2022-028-PSA-97
Organisation
Kubicek Balloons
Action Status
Closed
Action description

To address the safety issue, Kubicek Balloons advised the ATSB of the following safety actions implemented in May 2023:

  • The production manufacturer test inflation procedure was updated:
    • Roles and responsibilities of each person involved in the test process were more clearly defined.
    • All balloons with a modified deflation system (for example, change to vent design or vent aperture size) will be required to undergo a more comprehensive production inflation test (Level 2 test):
      • The scope and methodology of this test will be defined by the designer of the modification and submitted to a compliance verification engineer for review and approval. The approved methodology will then be communicated to the test inflation manager and test pilot.
      • This test procedure requires the use of 2 temperature sensors and includes guidance for correctly positioning the temperature sensors.
      • The completed test report will be used as evidence for the modification’s compliance with affected certification requirements.
    • The production test for standard balloons (that is, balloons with no modifications affecting flight characteristics) has been amended. The minimum envelope temperature requirement has been removed and replaced with a specific weight to be placed into the basket depending on the size of the balloon envelope. The balloon will be heated until equilibrium is achieved and the weight is lifted off the ground. Lifting the same weight allows the pressure difference between the inside and outside of the envelope to remain the same in changing external conditions and focuses only on the difference needed to tighten the envelope fabric to conduct the functional checks of the deflation system and rotation vents.
  • Production quality control checklist updated:
    • After a balloon is manufactured, an additional checklist item for quality control was added – this is to verify the type of modification (whether it is just a change of fabric colours, or if it effects on the technical design) and the required inflation test type. In case of any discrepancies, quality control must contact the responsible designer and ask for clarification.
  • Temperature sensors are now calibrated annually – the required inspection date is controlled automatically via an internal IT system accessible to all staff.

Kubicek Balloons is asked to provide advice during the directly involved party process of any other significant safety actions it has undertaken related to this occurrence.