Devastating crash at O'Hare 30 years ago leaves legacy of safety
If you think the news is dark these days, try going back 30 years, when on May 25, 1979, it must have literally seemed as if the sky was falling with the crash of American Airlines Flight 191 just outside O'Hare International Airport.
The Chicago area had just endured one of the harshest winters on record, one that had swept out Chicago Mayor Michael Bilandic and replaced him with Jane Byrne, a winter that had also seen 29 bodies dug out from under John Wayne Gacy's home.
The economy was in turmoil, with long lines at the limited number of gas stations that were open and inflation surging toward double-digit levels.
The Islamic revolution was in full swing in Iran, with street demonstrations that would lead to the hostage crisis at the U.S. Embassy in October. In March, the nuclear reactor at Three Mile Island, Pa., had suffered a partial meltdown. The anxious public mood was reflected in feature films like "The China Syndrome" and the original "Alien."
And just when things seemed on the verge of a spring revival, on a sunny Friday to open the Memorial Day weekend with temperatures hovering around 70, with Arlington Park set to open its 53rd season and Arlington Lakes Golf Club opening for the first time, it happened. An American Airlines DC-10, Flight 191 bound for Los Angeles, fell from the sky and crashed in an unincorporated area between Des Plaines and Elk Grove Village, not a mile from the O'Hare runway where it had taken off, killing 273 persons.
The disaster did trigger something of a revival, in the form of improved air safety resulting from the detective work to determine just how it happened. If 30 years later AA Flight 191 remains the worst aviation accident on U.S. soil, that's a good thing.
Flight 191 took off just after 3 p.m. on May 25, 1979. In the process, however, it lost the engine off its left wing, dropped behind on the runway. Nevertheless, the plane reached an altitude of 325 feet before abruptly rolling left and diving into what had once been Ravenswood Airport, just short of a mobile-home park and a field of Amoco Oil fuel tanks beyond. With its own tanks topped off for a flight to the West Coast, the plane exploded in a fireball that witnesses said could be seen in the Loop. It incinerated everything and everyone onboard, 271 persons, and two more on the ground in a converted hangar belonging to the Courtney-Velo Excavating Co. at 320 W. Touhy Ave.
The first responders on the scene later said they had trouble finding the crash site until the smoke cleared and they realized they were standing in the midst of it, that there was next to nothing left.
Officer Ken Burger, of the Chicago Police Canine Training Facility that is still there on that stretch of Touhy, later described "an acrid smell in the air - of burning fuel, burning flesh," and paramedic John Heavey said he saw only parts of bodies, soaked in fuel.
Hospitals were put on alert and ambulances rushed to the scene, but as later with Sept. 11 - the world's worst aviation disaster as a willful terrorist attack - they waited for patients that never came; there were no survivors.
The Rev. Richard Homa left St. Zachary Catholic Church in Des Plaines to rush over to administer last rites, only to be greeted by a doctor who walked past him with black bag in hand saying, "Father, there's nothing we can do."
The question was what had been done, and how had it happened?
The powerful McDonnell Douglas DC-10, counterpart to the Boeing 747, had been designed to take off and fly in the event of a failure of one of its three engines.
The crew was highly experienced: flight engineer Alfred Udovich, 56, co-pilot James Dillard, 49, and Capt. Walter Lux, 53, who had accepted the assignment at the last moment in a swap with another pilot.
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What National Transportation Safety Board and Federal Aviation Administration investigators had to go on was the engine on the runway, a black-box cockpit recording that shorted out after a single word, "Damn," apparently uttered by Dillard, who was assigned the takeoff and landing, and a macabre set of pictures taken from an O'Hare observation deck by amateur photographer Michael Laughlin of Toronto. One showed the plane perpendicular to the ground just above an airport hangar with smoke and fluid streaming from the left wing, another the ensuing fireball.
"After I had taken all the pictures, I just stood there stunned, wondering to myself, 'Did this really happen? Did I really take these pictures? Did that plane really crash?'" Laughlin told United Press International.
"I thought, 'There has to be some other explanation for this crazy airplane turning over and for all that fire.' I just couldn't believe it. I just stood there shaking."
The explanation turned out to be not what the NTSB's lead point man, Woody Driver, originally believed. He blamed a fractured bolt for the loss of the engine.
Yet NTSB investigator Michael Marx, a metals expert, believed the fractured bolt was a result, not the cause of the lost engine, and when he was proved right, it enabled them to reconstruct the "chain of error" that brought about the crash.
The plane had been serviced eight weeks earlier at an AA facility in Tulsa, Okla. There, crews pressed to trim man-hours had come up with a shortcut in servicing the wing engines.
While McDonnell Douglas had stipulated that the engines should first be removed from the pylon strip connecting them to the bottom of the wings, mechanics were saving a step by removing them together with a forklift, then rocking them back into place.
In the case of Flight 191, an unusually ragged procedure, including a change in work shifts, had led to a stress fracture in the flange attaching the pylon to the rear of the wing. Over eight weeks of subsequent flying, it worsened until it snapped.
When the engine came loose at the back, thrust propelled it forward and sent it spinning end over end over the top of the wing. In the process, it ripped a hole in the front of the wing, severing both the hydraulics system and key electrical lines and warning signals running to the cockpit (thus the short-circuited black-box recording).
Without the hydraulics, the struts lifting the plane into the air retracted on the left wing, without warning to the cockpit.
That's why the plane initially lifted off, then rolled as the left wing basically stalled while the right continued to provide lift.
In dozens of later flight simulations, not a single pilot saved the flight without knowing exactly what the problems were beforehand.
Yet those who died, in many ways, paid with their lives for what became a safer industry.
The detective work to determine the actual cause of the crash led AA to adopt new maintenance procedures and McDonnell Douglas to change the DC-10's design, not only in the way the engines were attached, but in adding second and third layers of redundancy to much of the hydraulic and emergency warning systems, changes made in other plane designs as well.
For the record, AA was fined $500,000 for its maintenance procedures, although the DC-10's design and the FAA's failure to police the industry better were also blamed. The amount of damages paid out by AA and McDonnell Douglas has never been made public.
The tendency to make things right after a disaster has been called "tombstone aviation" by some in the industry, but it's not unique to air travel. Just as the 1903 Iroquois Theater fire in Chicago, which killed more than 600 people, led to safety procedures we still take for granted today at the movies - such as readily available and clearly marked exits - and the Eastland disaster in the Chicago River in 1915, killing more than 800, led to changes in boat design and capacity limits, the same goes for air disasters.
"We learn from our mistakes," says Fred Arenas of Arlington Heights, a retired 32-year pilot with TWA.
Without blaming the AA mechanics who had adopted that maintenance shortcut, Arenas mentions them. "That's a hard pillow those guys have to sleep with the rest of their lives," he says, "knowing of course they didn't get up that morning with this in mind. It's a sobering thing for everybody in the business."
And it's led to a safer air industry, despite waves of deregulation and economic hardships. Sept. 11 aside, only one U.S. flight has joined the list of worst air disasters in the 2000s: the AA A300 Airbus Flight 587 that crashed in Belle Harbor on takeoff from New York City's JFK Airport in 2001, later attributed to pilot error and bad design.
"Certainly, for every incident where there's a loss of life, no matter who the carrier is, the industry is sadder, and the carrier works even harder that such a situation never happens again," said AA spokeswoman Mary Frances Fagan.
Still, it goes back and forth, the battle between air safety and economic viability in a competitive industry.
Arenas spent 27 of his 32 years as a union representative serving in negotiations. "Nothing occupies our energies as union people more than air safety," he recalls, adding, "To try to convince the airline president to spend millions of dollars to try to prevent an accident that hasn't happened yet is a tough sell."
Tom Hoban of the Allied Pilots Association, AA's pilots union based in Dallas, adds that calling the air industry safer these days is "a sweeping generalization" and says "we're not spending what we used to on safety and maintenance," although an American Airlines official says that's "simply untrue."
The perpetual need to retain vigilance is just one of the many reasons to preserve the memory of those 273 persons who died 30 years ago in what is now a fenced-off field of the Metropolitan Water Reclamation District between Des Plaines and Elk Grove Village.
Monday, we'll revisit some of the more personal reasons, as well.
Worst U.S. air disasters
Sept. 11, 2001
American Airlines and United Airlines 767s hit NYC's World Trade Center, more than 2,700 killed.
May 25, 1979
American Airlines DC-10 crashes near O'Hare, 273 killed.
Nov. 12, 2001
American Airlines A300 crashes in Belle Harbor, N.Y., 265 killed.
Sept. 17, 1996
TWA 747 crashes off East Moriches, N.Y., 230 killed.
Sept. 11, 2001
American Airlines 757 hits the Pentagon, 189 killed.
World's worst air disasters
Sept. 11, 2001
World Trade Center, More than 2,700 killed.
March 27, 1977
Pan Am and KLM 747s collide on ground in Canary Islands, 583 killed
Aug. 12, 1985
Japan Air Lines 747 crashes on Mount Osutaka, Japan, 520 killed.
Nov. 12, 1996
Saudi 747 and Kazakhstan 176 collide over India, 349 killed.
March 3, 1974
Turkish Airlines DC-10 crashes in France, 346 killed.
<div class="infoBox"> <h1>More Coverage</h1> <div class="infoBoxContent"> <div class="infoArea"> <h2>Photo Galleries</h2> <ul class="gallery"> <li><a href="/story/?id=294827">Images from the Flight 191 crash </a></li> </ul> <h2>Video</h2> <ul class="video"> <li><a href="/multimedia/?category=9&type=video&item=354">Former Daily Herald reporter Paul Marcotte on Flight 191 crash</a></li> <li><a href="/multimedia/?category=9&type=video&item=353">Former Daily Herald photographer Dave Tonge on Flight 191 crash</a></li> </ul> <h2>Stories</h2> <ul class="links"> <li><a href="/story/?id=295468">Flight 191, an ill-fated number <span class="date">[05/24/09]</span></a></li> <li><a href="/story/?id=295190">30 years later, no memorial marker for Flight 191 <span class="date">[05/21/09]</span></a></li> <li><a href="/story/?id=295190">Now a pilot, he was in high school when he saw 191's smoke plume <span class="date">[05/24/09]</span></a></li> </ul> </div> </div> </div> Now a pilot, he was in high school when he saw 191's smoke plume