About Safety

Contract Mechanic Sucked into Engine, Killed

A mechanic, Donald Buchanan, working for Julie's Aircraft Services of El Paso, Texas as a contract maintenance provider for Continental Airlines, was sucked into a 737 engine and killed January 16, 2006. Buchanan was part of a team of three mechanics responding to a discrepancy report of an oil leak made by the first officer of the flight, according to Bill Gamble, air safety investigator for the National Transportation Safety Board (NTSB). One of the three, not Buchanan, was receiving on the job training at the time.

Buchanan reportedly confirmed that a fluid puddle beneath the engine was oil. The cowling was partially removed and the flight crew initiated an engine run so that the maintenance team could determine the severity of the leak. "Witnesses said that two mechanics were stationed beneath the engine during the engine run, counting drops per the maintenance manual to determine if it was within limits," said Gamble. "There was a thump, and vibration felt throughout the aircraft. The flight crew initiated an immediate shut down," he added.

The inspection taking place required two mechanics to be positioned, one on each side, underneath the engine while the engine was run and drops of oil were counted. Both Buchanan and the second mechanic were in a safe zone (see diagram) with Buchanan on the outboard side. The engine was believed to be at some power setting above idle but the flight data recorder information was not yet available.

One witness said he saw Buchanan lose his hat and reach for it. "Mr. Buchanan stood up for whatever reason. It has yet to be determined," said Gamble. The result of that action was that he was sucked into the inlet and the aftermath was described by Gamble as "horrific."

One experienced maintainer said of the CFM56 (the engine on the 737), "In 1986 when the new [737] models were being introduced, we lost 2 rampers into them. [At the airline] there was a rapid awareness training program put in place to make all aware." This source added, "When we worked under the engine cowls during runs, we always wore a safety belt that we would latch to the engine case. These engines suck up everything and anyone indiscriminately even at idle." -- By Joy Finnegan