Narrative:

Flight departed on the evening of sep/mon/02 for purposes of conducting an FAA assessment for approval of a proposed sfo rnp RNAV approach. The aircraft had a total of 12 persons on board: 5 FAA and 7 company personnel. We were returning to sea due to WX going below the required ceiling for the sfo rnp procedure. I was in the left seat, with company pilot in the right seat. Both observer seats were occupied by FAA personnel and the flight deck door was closed. We conducted the ILS runway 16R approach. Following a smooth touchdown, thrust reversers were deployed and light braking applied. The initial landing callouts of 'speed brakes' and '2 lights' were made, followed by the speed callouts. During the speed callouts, I heard a loud bang behind the flight deck, but did not look behind me as I was the PF. Exiting the runway, I heard the voice of a company employee checking flight deck status and stating that another employee had sustained a foot injury. Shortly thereafter, this person also stated that the injury included a possible broken bone and bleeding, at which point we requested (via operations) medical assistance to meet us at the gate. On the taxiway, I glanced over my shoulder and could see that at least one of the flight deck door blowout panels was open, but the door was still closed. It was at this point I learned that a galley cart had impacted the flight deck door. We taxied to the gate and were met by company and medical personnel. The injured employee was treated by medics, then taken to the hospital. Upon leaving the flight deck, we held a debrief with the personnel on the flight. The other pilot and I drove the center aisle jump seat occupant to a nearby hospital for a medical evaluation. He had been seated in the aisle jump seat when the cart struck the door behind him. After the evaluation, he stated that he was not injured, and we drove him to his hotel. Supplemental information from acn 560167: there was a loud explosion from behind the cockpit door. I looked back and saw that the cockpit door was shoved in and the upper 'blowout' panel was positioned forward against FAA observer's neck. Company observer jumped up from first class seating position and pushed the panel forward to make sure we were alright. He then informed us company technical development manager who was sitting in seat had sustained an injury to her left foot and wanted to know where the first aid kit was. I called operations for medical assistant. FAA observer also had sustained a bruise to the lower back area and a bump to the back of his head. The aft center service cart had broken loose from its location and traveled the full length of the aisle and struck the cockpit door. Injured passenger had her legs crossed so that her left foot was slightly extended into the aisle allowing the cart to strike her heel before coming to a stop against the cockpit door. 5 FAA and 7 company employees total on board.

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Original NASA ASRS Text

Title: AN ACR, CONDUCTING A NAV TEST FLT RPTED THAT A GALLEY CART DEPARTED THE GALLEY AND INJURED A COMPANY OBSERVER AND AN FAA OBSERVER.

Narrative: FLT DEPARTED ON THE EVENING OF SEP/MON/02 FOR PURPOSES OF CONDUCTING AN FAA ASSESSMENT FOR APPROVAL OF A PROPOSED SFO RNP RNAV APCH. THE ACFT HAD A TOTAL OF 12 PERSONS ON BOARD: 5 FAA AND 7 COMPANY PERSONNEL. WE WERE RETURNING TO SEA DUE TO WX GOING BELOW THE REQUIRED CEILING FOR THE SFO RNP PROC. I WAS IN THE L SEAT, WITH COMPANY PLT IN THE R SEAT. BOTH OBSERVER SEATS WERE OCCUPIED BY FAA PERSONNEL AND THE FLT DECK DOOR WAS CLOSED. WE CONDUCTED THE ILS RWY 16R APCH. FOLLOWING A SMOOTH TOUCHDOWN, THRUST REVERSERS WERE DEPLOYED AND LIGHT BRAKING APPLIED. THE INITIAL LNDG CALLOUTS OF 'SPD BRAKES' AND '2 LIGHTS' WERE MADE, FOLLOWED BY THE SPD CALLOUTS. DURING THE SPD CALLOUTS, I HEARD A LOUD BANG BEHIND THE FLT DECK, BUT DID NOT LOOK BEHIND ME AS I WAS THE PF. EXITING THE RWY, I HEARD THE VOICE OF A COMPANY EMPLOYEE CHKING FLT DECK STATUS AND STATING THAT ANOTHER EMPLOYEE HAD SUSTAINED A FOOT INJURY. SHORTLY THEREAFTER, THIS PERSON ALSO STATED THAT THE INJURY INCLUDED A POSSIBLE BROKEN BONE AND BLEEDING, AT WHICH POINT WE REQUESTED (VIA OPS) MEDICAL ASSISTANCE TO MEET US AT THE GATE. ON THE TXWY, I GLANCED OVER MY SHOULDER AND COULD SEE THAT AT LEAST ONE OF THE FLT DECK DOOR BLOWOUT PANELS WAS OPEN, BUT THE DOOR WAS STILL CLOSED. IT WAS AT THIS POINT I LEARNED THAT A GALLEY CART HAD IMPACTED THE FLT DECK DOOR. WE TAXIED TO THE GATE AND WERE MET BY COMPANY AND MEDICAL PERSONNEL. THE INJURED EMPLOYEE WAS TREATED BY MEDICS, THEN TAKEN TO THE HOSPITAL. UPON LEAVING THE FLT DECK, WE HELD A DEBRIEF WITH THE PERSONNEL ON THE FLT. THE OTHER PLT AND I DROVE THE CTR AISLE JUMP SEAT OCCUPANT TO A NEARBY HOSPITAL FOR A MEDICAL EVALUATION. HE HAD BEEN SEATED IN THE AISLE JUMP SEAT WHEN THE CART STRUCK THE DOOR BEHIND HIM. AFTER THE EVALUATION, HE STATED THAT HE WAS NOT INJURED, AND WE DROVE HIM TO HIS HOTEL. SUPPLEMENTAL INFO FROM ACN 560167: THERE WAS A LOUD EXPLOSION FROM BEHIND THE COCKPIT DOOR. I LOOKED BACK AND SAW THAT THE COCKPIT DOOR WAS SHOVED IN AND THE UPPER 'BLOWOUT' PANEL WAS POSITIONED FORWARD AGAINST FAA OBSERVER'S NECK. COMPANY OBSERVER JUMPED UP FROM FIRST CLASS SEATING POS AND PUSHED THE PANEL FORWARD TO MAKE SURE WE WERE ALRIGHT. HE THEN INFORMED US COMPANY TECHNICAL DEVELOPMENT MGR WHO WAS SITTING IN SEAT HAD SUSTAINED AN INJURY TO HER L FOOT AND WANTED TO KNOW WHERE THE FIRST AID KIT WAS. I CALLED OPS FOR MEDICAL ASSISTANT. FAA OBSERVER ALSO HAD SUSTAINED A BRUISE TO THE LOWER BACK AREA AND A BUMP TO THE BACK OF HIS HEAD. THE AFT CTR SVC CART HAD BROKEN LOOSE FROM ITS LOCATION AND TRAVELED THE FULL LENGTH OF THE AISLE AND STRUCK THE COCKPIT DOOR. INJURED PAX HAD HER LEGS CROSSED SO THAT HER L FOOT WAS SLIGHTLY EXTENDED INTO THE AISLE ALLOWING THE CART TO STRIKE HER HEEL BEFORE COMING TO A STOP AGAINST THE COCKPIT DOOR. 5 FAA AND 7 COMPANY EMPLOYEES TOTAL ON BOARD.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.