An embraer 145 #1 engine bleed air duct clamp failed during climb out, filling the cockpit and cabin...

Attributes
ACN	643056
Time
Date	200412
Day	Wed
Local Time Of Day	0601 To 1200
Place
Locale Reference	atc facility : zzz.tracon
Altitude	msl single value : 9000
Environment
Flight Conditions	VMC
Light	Daylight
Aircraft 1
Controlling Facilities	artcc : zzz.artcc
Operator	common carrier : air carrier
Make Model Name	EMB ERJ 145 ER&LR
Operating Under FAR Part	Part 121
Flight Phase	climbout : initial
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	flight crew : captain oversight : pic
Experience	flight time last 90 days : 135 flight time total : 3500 flight time type : 1600
ASRS Report	643056
Person 2
Affiliation	company : air carrier
Function	flight crew : first officer
Events
Anomaly	aircraft equipment problem : critical other anomaly other anomaly other anomaly other
Independent Detector	other flight crewa other flight crewb
Resolutory Action	flight crew : overcame equipment problem flight crew : landed in emergency condition flight crew : declared emergency other
Consequence	other other
Supplementary
Problem Areas	Aircraft
Primary Problem	Aircraft

Narrative:

Passing through about 9000 ft MSL on climb out, we got bleed air leak message for both engines #1 and #2. While we were going through the checklist that dealt with this problem, we heard a loud pop, which was followed by smoke in the cockpit and cabin. We donned our oxygen masks, declared an emergency and turned back. With all bleed valves closed, the smoke did not seem to get worse and by the time we landed, only a strong odor remained. On our descent, we got a message saying the #1 radar altimeter had failed. TCASII, GPWS, and the landing gear warning system also failed since these are connected to the #1 radar altimeter. We later found that the leak had occurred in the ducting from the #1 engine. A large gap in the ducting was created when a clamp that holds together 2 pieces of tubing had broken. The air coming out of the leak from the #1 side was sufficient enough in volume and temperature to set off the leak sensor for the #2 engine bleed system. The leak sensors for the #1 and #2 sides were about 1.5 ft apart. The radar altimeter was located in this area. All of its external wiring connections had been melted. The only other damage found was done to the #1 bleed leak sensor.

Original NASA ASRS Text

Title: AN EMBRAER 145 #1 ENG BLEED AIR DUCT CLAMP FAILED DURING CLBOUT, FILLING THE COCKPIT AND CABIN WITH SMOKE AND FORCING THE CREW TO RETURN TO THE DEP ARPT.

Narrative: PASSING THROUGH ABOUT 9000 FT MSL ON CLBOUT, WE GOT BLEED AIR LEAK MESSAGE FOR BOTH ENGS #1 AND #2. WHILE WE WERE GOING THROUGH THE CHKLIST THAT DEALT WITH THIS PROB, WE HEARD A LOUD POP, WHICH WAS FOLLOWED BY SMOKE IN THE COCKPIT AND CABIN. WE DONNED OUR OXYGEN MASKS, DECLARED AN EMER AND TURNED BACK. WITH ALL BLEED VALVES CLOSED, THE SMOKE DID NOT SEEM TO GET WORSE AND BY THE TIME WE LANDED, ONLY A STRONG ODOR REMAINED. ON OUR DSCNT, WE GOT A MESSAGE SAYING THE #1 RADAR ALTIMETER HAD FAILED. TCASII, GPWS, AND THE LNDG GEAR WARNING SYS ALSO FAILED SINCE THESE ARE CONNECTED TO THE #1 RADAR ALTIMETER. WE LATER FOUND THAT THE LEAK HAD OCCURRED IN THE DUCTING FROM THE #1 ENG. A LARGE GAP IN THE DUCTING WAS CREATED WHEN A CLAMP THAT HOLDS TOGETHER 2 PIECES OF TUBING HAD BROKEN. THE AIR COMING OUT OF THE LEAK FROM THE #1 SIDE WAS SUFFICIENT ENOUGH IN VOLUME AND TEMP TO SET OFF THE LEAK SENSOR FOR THE #2 ENG BLEED SYS. THE LEAK SENSORS FOR THE #1 AND #2 SIDES WERE ABOUT 1.5 FT APART. THE RADAR ALTIMETER WAS LOCATED IN THIS AREA. ALL OF ITS EXTERNAL WIRING CONNECTIONS HAD BEEN MELTED. THE ONLY OTHER DAMAGE FOUND WAS DONE TO THE #1 BLEED LEAK SENSOR.

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.

An embraer 145 #1 engine bleed air duct clamp failed during climb out, filling the cockpit and cabin with smoke and forcing the crew to return to the departure airport.