Ultimate Airport Dubai (2013) s03e06 Episode Script

1
NARRATOR: In this episode,
a tiny bolt threatens to cost
Emirates millions of dollars.
ANDREW: He dropped the bolt.
LEIGH: We've got
to find that bolt.
ANDREW: This is one of
your worst nightmares.
NARRATOR: Tensions run high
in a make or break test.
WISSAM: There is no second
chance to save people's life.
NARRATOR: And delays could
de-rail the airport's epic
concourse construction project.
MYLES: Your problem.
Now this is embarrassing for all
of us. Complete disaster for me.
NARRATOR: Dubai
International Airport.
The busiest global hub on the planet.
Staying on top takes a crack team.
PHIL: No-one else in the world is
doing it, but everybody else in the
world is watching us.
MEL: We have births, we have
deaths, the whole spiel.
HASSAN: It is very
dangerous because it can explode any time.
MYLES: This concourse
will help Dubai Airports stay number one.
NARRATOR: It's the job of
90,000 staff from all over the world,
to make this the ultimate airport.
Here at Dubai International,
every passenger, every bag,
and every plane depends on the
world's most advanced technology
to pass through the airport smoothly.
But when it fails, operations can grind
to a halt, and sometimes even the tiniest
part can cause the most serious trouble,
both on the ground, and in the air.
LEIGH: Alright, I'm just
gonna set the flight deck up for the test.
Fuel control switch is at cut off.
NARRATOR: Line maintenance engineer,
Leigh Faulkner has been called to a
Boeing 777-300 that's been grounded
due to two different engine faults.
LEIGH: Emirates Echo Juliet.
NARRATOR: He needs to fix
both problems quickly.
The aircraft is due to fly to
Zurich with over 300 passengers in
just five hour's time.
LEIGH: Auto start has
to be selected, off.
NARRATOR: First, he must
tackle the right engine anti-ice valve.
LEIGH: The valve that controls
the air that allows the hot air to stop
ice from forming on the front of the
engine, that is opening very slowly.
NARRATOR: The anti-ice valve needs to open
quickly when the plane is at high altitude.
At 35,000 feet temperatures
can drop to minus 70 degrees,
causing ice to form.
If solid ice built up on the engine,
it could be sucked into the blades,
causing severe damage.
With two problems on the same aircraft,
Leigh needs another pair of hands.
Veteran engineer, Andy Clark has
come to help out with the anti-ice valve.
ANDREW: And what the
anti-ice valve does, is allow hot air
to come into this area
on the inlet of the engine.
It's a bit like the defroster on your car.
But a lot hotter.
When this is on, you don't wanna put your
hand here, you'll leave your skin behind.
NARRATOR: To keep this aircraft
leaving on time, Andy and Leigh need to
change the whole valve.
The replacement should be
on board, but they can't find it.
LEIGH: It's not in the file,
it's not in the closet.
It's not in the cupboards.
We're missing the valve and the
filter which really, all we have is seals.
You see, this moment in
time I would normally swear.
But I'll refrain from it.
NARRATOR: Without the
replacement immediately to hand,
the team pushes
ahead with removing the old
valve while they wait for the new parts.
ANDREW: So how
long do you think? About ten minutes?
RASHEED: Ten minutes.
NARRATOR: At over nine feet in
diameter, this is the largest and most
powerful passenger jet
engine in the world.
Working on any part
deep inside it is a highly skilled job.
LEIGH: We've removed the valve, as
I suspected the union on the valve and
the pipe were cross-threaded.
That's why the air is leaking, so
it's not operating the valve correctly.
The tube is damaged as well, so
now we've got to replace the tube.
ANDREW: What's the access
look like for that?
LEIGH: Absolutely terrible.
NARRATOR: The job has just become
even more of a challenge and the tube
is surrounded by up to 25,000 other parts.
And it's such an inaccessible
part of the engine that removing it is
like performing open
heart surgery, blindfolded.
LEIGH: We now have a hole in
the engine, because this sits on top.
So we now, because we're gonna be
working there and taking screws out,
we have to be careful of
dropping a screw in the hole.
Because if we drop the screw in the
hole, I'm afraid it's an engine change.
It runs in the, probably into the tens of
millions rather than the single millions.
NARRATOR: This is
not just about money.
It's also about the safety
of the passengers and crew.
With the 22 blades spinning in flight,
just one loose bolt
could rip the engine apart.
ANDREW: Oh, cheers mate.
NARRATOR: Andy is
taking no chances.
He plugs the hole where the
anti-ice valve used to be with a blanket.
LEIGH: Alright, that's
completely blocked it Andy.
ANDREW: It's completely
blocked, yeah.
LEIGH: OK yeah good. Don't mind
if it drops and it falls on the floor,
but we can't have it left in the engine.
NARRATOR: Between them Andy and
Leigh have over 70 years of experience
working as engineers.
But trainee Rasheed is in at the deep end.
ANDREW: He dropped the bolt.
LEIGH: He dropped the bolt.
JO: Hi Mary, Jo.
Hey, can I speak to Augy again please?
Thank you.
NARRATOR: Inside the terminal,
airport services
manager Jo Di Biasi has a colossal excess
baggage issue on her hands.
JO: Hey, tell me, this
family with an infant.
Refusing to pay excess.
What's going on?
Ok, 60-something kilos of excess to pay.
I'm gonna come through now, Ok,
can you get the Chinese speaker there?
NARRATOR: Jo never knows which of
the 130,000 passengers that pass each day
through terminal three could
present her with a challenge.
Today she has a family stranded
in the terminal with a baby.
They've arrived on another airline
from China, but are travelling onto Jordan
on an Emirates flight.
They have to pay for their excess baggage,
but don't appear to have the money.
JO: Can he ring anyone for
money if I give him the phone?
Can he get money sent over?
INTERPRETER: So, you can
give her his phone to call?
JO: Yeah, he can use, yeah he can
ring someone, that's not a problem.
NARRATOR: The family has a
mammoth 67 kilos of excess baggage.
That's 148 pounds.
And unless they pay
the hefty $1300 fine they won't be allowed
to complete their journey.
INTERPRETER: He doesn't
have enough money to have,
to pay for this excess baggage.
JO: But then, see
this is a problem.
Because they got
accepted from another airline,
you know, they're still the
other airline's responsibility,
so we're trying to help
them as much as we can here.
I can't even waiver all that excess
baggage, as much as I'd love to.
INTERPRETER: What
about one baggage?
Like, 24 kilograms like that?
JO: But that's like,
you know, I can't.
There's no way, no, I can't.
NARRATOR: Airlines
have to be strict with their excess fees.
With every extra kilo on board,
planes burn more fuel,
costing more money and doing
more harm to the environment.
Jo is in no position to
cancel a $1300 excess fee.
So she calls the
Chinese airline to see if they can help.
JO: We've got a family, three
adults and one infant going to Amman.
What your staff did in China
was through-check the baggage.
NARRATOR: The Chinese airline only charged
the family for their excess up to Dubai,
and not for their connecting
flight with Emirates.
Jo thinks they're at fault, but
so far, they're not playing ball.
JO: You can imagine having a two
month year old baby in an airport.
Now they're here for another nine hours.
They weren't briefed about anything.
It's not really fair
on the passenger, yeah?
Yeah, just let me finish yeah?
Just let me finish.
They weren't told so they've come
here, and they're stuck in the airport.
They've missed the
flight, 'cause they had not enough funds.
So it's not really fair
that you've bought them in.
Yeah that's fine.
Yeah, we got past that point,
yeah we got past that point.
We're still going around in circles.
So there's nothing you
can do for the passenger?
Are you able to come to Terminal Three?
No one at all can come to
speak to these passengers?
Yeah, we don't wanna have a fight,
I really need to
speak to these passengers,
but thanks anyway for
trying to help me OK?
He's telling me it's Emirates fault,
that we should tell passengers that
they need to pay excess baggage.
It's not a blaming game,
it's not about whose fault it
is, it's about we've got three
adults here and one infant,
that are here in Dubai,
they need to wait nine hours.
And we've got no solution for them.
NARRATOR: Dubai International
has ambitious plans to grow.
And the new billion dollar concourse
D will help to raise capacity from
75 to 90 million passengers per year.
Today is a key milestone
in its construction.
MYLES: We're walking towards the gate
nine and ten where we have a trial today.
NARRATOR: Myles Jones is doing his inspection
before a crucial boarding gate trial.
MYLES: We'll be bringing
in ten passengers,
with boarding passes, and
getting them onto an aircraft.
NARRATOR: On this new concourse,
they've designed four of the gates
to board two planes at once,
to make aircraft boarding more efficient.
The gates can also be used
for high security flights,
to comply with regulations for
aircraft travelling to the US and the UK.
And it's one of these
gates that Myles needs to trial today.
MYLES: How's it looking?
NARRATOR: But the minute his inspection
begins, he's off to a bad start.
MYLES: What happened here?
We got a problem where one of our
contractors, and he's just blocked the door.
So really I'm not happy about this.
And seeing contractor with a scaffold out
the front, and pulling down a sign is a
complete disaster for me.
NARRATOR: Today, Myles has come to inspect
signage, electronics, and security.
If they're not ready, the high
security gate trial will fail.
MYLES: Hey Rakesh.
Rakesh, where are your people man?
Come on.
It's, it's 8:00
and you've not started work.
You've got beam seats.
You've got these black beam
seats in the way of the gate.
You can't have a contractor come at 8:30
when they're meant to be here at 7:00,
and they're already behind.
NARRATOR: The last thing Myles needs is
to be chasing the 6,000 contractors that
work on the concourse.
But here at the gate, jobs that
are crucial to the trial's success,
have not been completed.
MYLES: Well this is one small problem,
where we have a breach of security.
So, glass panel needs to go in here asap.
NARRATOR: There's another key glass door
missing at the side entrance to the gate.
So Myles needs barriers in
their place to block the way.
MYLES: Did you get
the delivery yesterday from downstairs?
He didn't do it?
MAN: No, nothing happened.
MYLES: Hey, the stainless
steel tensile barriers were meant to
be delivered yesterday.
We have about 1,000 of them downstairs.
So now he's had to steal them from
another gate which defeats the purpose
of what we're doing.
NARRATOR: As the senior manager
on the concourse, failures like this fall
on Myles' shoulders.
To add to his worries,
display screens are failing.
MYLES: It's coming on.
Why is this happening?
NARRATOR: But Myles' biggest
headache is that the signs for the gate
haven't been installed.
MYLES: This was all meant
to be done yesterday.
It's not a good impression to
be working last minute at a gate.
It's not the way we wanna operate.
Not good.
NARRATOR: There are
now just minutes until the trial begins.
MYLES: This is your problem.
We can't have these (bleep) ups.
And yesterday, this was
to be promised to be done.
Honestly, forget about the camera.
This is embarrassing for all of us.
NARRATOR: Back in the terminal,
Jo Di Biasi is still dealing with the
stranded Chinese family.
As they can't pay their
$1300 excess baggage fee,
they're resigned to
unpacking the bags themselves,
and leaving 148 pounds behind.
But that means getting
to their bags first.
JO: Sorry, sorry to interrupt,
but with the bags also,
they can't go to the
carousel and clear their bags
because they're Chinese passport holders.
They need visas for Dubai.
INTERPRETER: Mm hm.
JO: So they're gonna have to
explain to us what color their
bags are that they wanna go,
and hopefully it more or less
comes up to 100 kilograms.
But they can't clear Dubai
and go through their bags.
NARRATOR: In order to collect their
bags, they may have to leave the transit
area and go into Dubai.
But Chinese citizens cannot
enter Dubai without a visa.
But the passengers insist on
going through the bags themselves,
or they'll lose vital baby equipment.
Desperate for a solution to their dilemma,
Jo contacts her colleagues in
immigration, to try to call in a favor.
JO: If the father wants to fix his bags,
and work out which ones he throws away and
which one he keeps, how can
he get the visa downstairs?
Possible?
NARRATOR: The fate of this family could
now hang on Jo's powers of persuasion.
JO: Ok, thank you, thank you,
thank you, you're too nice.
All he'll have to do, is go downstairs, get
his bags, and be back in about four hours.
NARRATOR: Jo has convinced
immigration to issue a temporary visa.
She's even saved the family the $150 fee.
JO: Emirates will pay, as long as they get
their bags, go back up to check in and I'll
meet them at check in
to get them checked in.
INTERPRETER: OK, cool. OK.
JO: Alright?
The mother's staying here with her infant.
The brother and sister will be going
out to go through the bags, and hopefully
they can reduce their weight.
NARRATOR: The passengers are taken
to a high security area where they can
only access their bags under
close police supervision.
Here, they must lose
67 kilograms of luggage.
That's 148 pounds.
More than double the
emirates' baggage limit.
OFFICER: They need to empty a
minimum of 10 kilos out of each bag.
It's quite a huge quantity.
NARRATOR:
They're travelling with a young baby,
so there are lots of
things they desperately need.
OFFICER: We have removed
so far 30 kilos
and we still have to remove 35 more kilos.
NARRATOR: But they seem keen
to hold onto their exotic Chinese food,
to give them a taste of home
when they arrive in Jordan.
But it's highly likely the food
won't even make it out of the airport.
OFFICER: Those items will be
stopped at Amman airport by Customs.
Especially if it's unknown food
items they are going to throw it.
NARRATOR: Their supplies of
Chinese food fill multiple suitcases.
They have to remove all of it.
After an eight hour nightmare,
they are finally free to go.
And back at check in,
Jo has pulled some strings to help
with the baby on their onward journey.
JO: OK, the passengers have now been
re-booked, managed to get them the first
row of economy as well
which is quite lucky.
OK.
So can you tell them I've
got them the bassinet row
so they can put the baby in the first row.
(speaking in native language).
INTERPRETER: She's saying,
"Thank you again, you are very helpful."
JO: Oh that's alright.
That's alright.
You are doing it all, not me.
Thank you so much, alright?
Bye.
INTERPRETER: Thank you.
JO: Bye. Bye.
NARRATOR: Out on the apron, Andy
and Leigh have a desperate situation.
LEIGH: What's the matter Andy?
ANDREW: He dropped the bolt.
LEIGH: He dropped the bolt?
You're having a laugh?
ANDREW: No. He
dropped the bolt.
Yeah.
NARRATOR: Until
Andy and Leigh can locate the tiny bolt,
all work on this
777-300 engine is on hold.
LEIGH: However long it takes.
We've got to find that bolt.
If we can't find it, then it could
possibly lead to an engine change.
NARRATOR: This precision engineered
777-300 engine costs $24 million.
ANDREW: Not good.
Yeah, this is one of your worst nightmares,
'cause there's so many nooks and
crannies where it can hide.
The unfortunate thing is,
the color of the bolt is the
same as the color of the engine,
so it's gonna be hard to spot.
NARRATOR: This aircraft is
due to leave in four hours.
But until Andy can find that single bolt,
worth no more than a couple of dollars,
this $300 million plane
won't be leaving Dubai.
But it's not just the bolt
Leigh has to worry about.
The aircraft is also
reporting another fault.
This time, it's the thrust reverser.
LEIGH: Well, basically, we've got
two reverser faults on the aircraft.
If we don't fix one of them,
then we can't fly.
NARRATOR: The thrust reversers
act as an engine braking system,
to slow the plane down on landing.
When the 300 ton plane
hits the runway, the cowling slides open.
Air flow inside the
111,000 horsepower engines is diverted.
This redirects the thrust to help
decrease speed, putting less strain on the
tire brakes as they
work to stop the plane.
Engineer Fiaz is an avionics expert.
Before he can even
begin to make any repairs,
he needs to diagnose the problem.
LEIGH: You need
to test it again.
NARRATOR: He thinks there
could be an intermittent wiring fault.
If he's right, the electronics he needs
to fix are deep inside the bodywork
above the engine.
LEIGH: We need to look at
changing the isolation DCV.
NARRATOR: Changing this
part is another huge challenge for Leigh.
LEIGH: Unfortunately, in
the manual it just says,
"Undo the unions
and remove the unit."
It doesn't come out.
You have to remove the pipework
and then you can get the unit out.
Added to that, we haven't got one here.
It's a five, six hour job.
FIAZ: Just grab that part.
NARRATOR: This aircraft is supposed to
be ready to fly in just four hour's time.
Leigh's day is going from bad to worse.
LEIGH: Just one of them days.
Just everything goes wrong.
It, sometimes you think,
it's all against you.
But it just goes like that occasionally.
NARRATOR: This flight is
now facing a heavy delay.
Over in the Emirates
network control center,
Peter Ishak is in danger
of having this aircraft
stuck on the ground indefinitely.
He needs a Plan B.
PETER: Now it's doing the
Zurich 85 in the afternoon.
Yeah, well they're forecasting
showers of rain and snow,
so there's gonna have
a contaminated runway,
so to have a thrust
reverser in-op is not ideal.
Now if engineering can't confirm
whether they can fix the aircraft,
then we've gotta find
an alternative aircraft.
The logistics of changing an aircraft here
are quite large, so we've set a deadline.
The pressure's really on now.
NARRATOR: On concourse D,
Myles has run out of time as the inspectors
arrive for his boarding gate trial.
MYLES: Everyone's here.
NARRATOR: Vid Gohil is one of the
inspectors on the airport trials team today.
It's up to her team to help
decide if the test succeeds or fails.
VIDHATRI: We designed the trials
so that it simulates real life operations.
It's a success if we
could get our criteria met.
My gut feeling is, we
probably won't be able to.
NARRATOR: Vid will be watching every
stage in the process with a critical eye.
The queuing procedure, boarding
pass scanning, and security checks.
If they don't all run as planned,
Myles will have some explaining to do.
VIDHATRI: Hi everyone.
Thank you for coming along to our trial.
Today we're gonna be trialing
security gate boarding.
If the passengers can then start queuing
and start doing the boarding process.
NARRATOR: But signage
is still not ready.
MYLES: Just put it
in there quickly.
I don't have time to wire it up now.
VIDHATRI: If anybody has a
boarding pass, can you start queuing?
NARRATOR: Myles is amongst the volunteers
taking part in today's boarding gate trial.
MYLES: I am gonna be acting as Abdullah,
going onto the flight to Air India.
The way it went this morning
I'd like to be flying.
NARRATOR: As the trial begins,
the boarding pass
checks seem to be going according to plan.
Computers are fully networked,
and the PA system is up and running.
But not all the electronics
are working correctly.
MYLES: What's happened
to that screen?
NARRATOR: Screens are down.
And signs haven't even been installed.
This alone could be enough
for the trial to fail.
MYLES: The sign annoying
is an understatement.
That was categorically promised to us
yesterday and we're sitting here with a
piece of paper with masking tape.
WOMAN: Have a nice flight.
MYLES: Thank you. WOMAN: Goodbye.
NARRATOR: As he passes through
the gate, an alarm is suddenly triggered.
MYLES: When I came through,
the staff, they didn't
use the right process,
they just held the door open.
And then it will just alarm.
And that's obviously for
a breach of security.
NARRATOR: A mistake of security
procedures may cause the trial to fail.
And Myles is not impressed.
MYLES: This is not
the way it should be.
These little things
make a huge difference.
NARRATOR: It's not just
Myles who's disappointed.
Vid has seen enough to
deliver a decisive verdict.
VIDHATRI: As an operational task, it
failed because we didn't have everything
that we would want to have.
NARRATOR: Vid's decision
is a major setback for Myles.
He has just 16 weeks
to finish the concourse,
but if his trials continue like this,
completion will be delayed.
MYLES: We've just started the trial
period, got a total of around 56 to do.
We need to get this a lot better than
what we are today and it's a huge task.
We have to deliver this concourse on time.
NARRATOR: Back outside,
Andy Clark is still desperately
searching for a tiny bolt.
ANDREW: Can we see it?
NARRATOR: Somewhere deep inside
the world's largest passenger jet engine.
LEIGH: We got it.
ANDREW: Got it? LEIGH: We got it.
ANDREW: I've still got a job.
That feels great.
LEIGH: I'd just like to think I, you
know, after 38 years, I still got it.
ANDREW: Hang around, we
might drop a second one.
NARRATOR: Now Andy can press
on with replacing his broken tube.
Which is the job he was trying
to do before the bolt was lost.
ANDREW: This is the
cause of our grief today.
This union here, inside is all chewed up.
NARRATOR: On the flight deck,
Fiaz has bad news
about the thrust reverser.
He's found yet another wiring fault.
FIAZ: After troubleshooting,
we decided
first of all we'd replace
the switches here.
NARRATOR: He has narrowed down
the problem to some micro switches inside
the control lever, so
they'll have to be replaced.
But it's a complex job,
involving new parts and difficult access.
This job could delay the
aircraft even further.
ANDREW: Wish me
luck, I'm going in.
NARRATOR: Replacing the faulty
tube which connects the anti-ice valve
ANDREW: Really, really
careful with this.
NARRATOR: Is one of the trickiest
jobs to carry out on a jet engine.
ANDREW: It is literally
keyhole surgery.
A lot of this type of
thing you can't see where you're working.
You do it entirely by touch.
Rasheed.
RASHEED: Yes.
ANDREW: Do you have
the bolt there please?
NARRATOR: This time,
Andy tries to fit the bolt.
ANDREW: I've dropped it.
LEIGH: You dropped it?
ANDREW: Yeah.
It popped out the back.
LEIGH: Is that real,
or are you joking?
ANDREW: No, no, I'm not.
I'm serious.
LEIGH: You're serious. OK.
ANDREW: It popped out the P clip.
LEIGH: OK.
NARRATOR: Now it's a senior
engineer who's dropped the bolt,
and it's fallen way out of reach.
ANDREW: Ah it's in
a very inaccessible area at the moment.
Right near where it popped out.
It didn't drop down anywhere.
LEIGH: Right, OK.
ANDREW: It's right on top
of the engine somewhere.
NARRATOR: Space is so tight
in that part of the engine,
that the bolt could be
impossible to retrieve.
LEIGH: Hopefully,
we'll find it soon.
Hopefully.
NARRATOR: Avionics expert Fiaz has
fixed the wiring problems affecting the
777-300's thrust reverser.
But five hours into their shift, Leigh
and Andy still can't find the $2 bolt,
which threatens to cost Emirates
an entire $24 million engine.
ANDREW: Hey Leigh.
LEIGH: Yeah.
ANDREW: I've found it.
LEIGH: About time you
did something today.
ANDREW: Thank you.
LEIGH: Well done mate.
ANDREW: Underneath
the unison ring.
NARRATOR: Finding the bolt
is only half the solution.
They still need to get it out.
ANDREW: Have we got any,
what do you call 'em?
LEIGH: Magnetic stuff?
We might have to go the hangar.
ANDREW: Or, a vacuum cleaner.
LEIGH: A vacuum cleaner.
ANDREW: Might be
able to suck it out.
LEIGH: Yeah.
Let's just have a look.
Just a bit, a small piece of rag, rolled
down, then we might be able to pull it out.
ANDREW: Yeah.
NARRATOR: It might be a $300
million aircraft, but Leigh has a low tech
solution to the problem.
LEIGH: Like three
strands, twisted.
Need to be able to bend
it like a coat hanger.
NARRATOR: With the scheduled
departure time looming,
in the network control center,
Peter is struggling to avoid having an
aircraft and 300 passengers stranded in Dubai.
PETER: Are we gonna make
that departure time?
MAN (over phone):
No, we will not.
PETER: We have
a deadline here.
Unfortunately, engineering can't give us
the aircraft we need to match the timelines.
We're gonna have to switch
the aircraft with the Vienna flight.
It's a slightly larger aircraft which
means that the Vienna flight will lose
approximately six seats, and
potentially six passengers will have to
go tomorrow morning.
NARRATOR: This one dropped bolt is
now costing Emirates time and money.
And it's affecting the travel
plans of paying passengers.
PETER: So it's a
lesser of two evils.
We don't want to leave passengers behind,
but at the same time, we've got to look
at the path of least resistance,
which means the minimum impact,
both to our passengers
and to the airlines.
NARRATOR: Helped by a
coiled piece of wire,
the bolt is finally within Leigh's reach.
LEIGH: It's just tickling it.
NARRATOR: Now he needs to retrieve
it, but he must be careful not to push
it even further into the engine.
ANDREW: Just comes out on
the rag. It's on the rag.
Careful. Got it?
LEIGH: Yeah, got it.
ANDREW: Alright. Result.
LEIGH: There's the little thing,
phew, glad that's over and done with.
Oh, it's not yet is it?
We ain't got it in.
ANDREW: No, we've
gotta put it in now.
LEIGH: The last few years, I haven't
dropped any bolts as bad as these,
and then get I two in one day.
Great.
And we've not even got it in yet.
So, don't want to count my chickens.
NARRATOR: Fitting this one bolt requires
all of Leigh's 38 years of experience.
He can't even see the hole,
so Andy must act as his eyes and
guide him through the maze of parts.
ANDREW: OK, you need to go
rearwards about a centimeter.
Up a centimeter.
Down a bit.
Up a, keep going backwards.
NARRATOR: They must be precise
for fear of dropping the bolt again.
ANDREW: OK.
LEIGH: I don't like to say
I'm good, but boy I'm good.
It's in.
I can't withdraw it.
ANDREW: No, no.
NARRATOR: Now
for the easy bit.
Using a tiny spanner, he
can refit the second bolt.
Then it's down to Rasheed to
install the anti-ice valve.
LEIGH: Pretty much are
on the home stretch.
Hopefully we can put
this thing to bed, and we can probably go
and have lunch about four hours late.
ANDREW: All done guv'nor.
LEIGH: Yeah. All done.
Thanks mate.
Thanks for your help.
ANDREW: No worries, cheers.
LEIGH: Well, but you
got there in the end.
ANDREW: Yeah, eventually.
LEIGH: Yeah, yeah.
NARRATOR: Repairing both the thrust
reverser and the faulty anti-ice valve has
taken Leigh and Andy over six hours.
Finally signed off as fit to fly, the
plane has now been rescheduled to leave for
Frankfurt, over ten hours after
its intended departure to Zurich.
ANDREW: I'm glad it's over.
I'm gonna get something to eat.
A few moments of heart
stoppers there when we dropped the bolts.
It all turned out good in the end.
LEIGH: Same place,
same time tomorrow.
NARRATOR: Today is the final practical
exam after eight grueling weeks of
firefighter training for
recruits Yared and Abdulrahman.
ABDULRAHMAN: This is the final tests
and we need to work together as a team.
If we fail to do that
then we'll fail the test.
NARRATOR: They've already faced search
and rescue drills, and a fuel blaze.
But now they face their
toughest challenge yet.
A cargo fire deep in the belly of one
of the world's largest fire simulators.
Where an inferno can
flare up to 3500 degrees.
YARED: Everything we have
to do depend on time.
So that we can reach
before anyone gets hurt.
NARRATOR: Training supervisor
Chris Ward has planned out the test.
CHRIS: The simulation that we're
running today is gonna be a fire inside
one of the storage
cages that you find inside any aircraft.
We've also set up two rescue dummies.
There'll be a rescue team trying to
rescue the dummies as quickly as possible.
NARRATOR: Today, the action will take
place in the cargo hold of this A380 model.
Here, Chris can activate 12 fires.
And fill whole decks with smoke.
This means he can create the
extreme conditions these trainees
could face as professional firefighters.
CHRIS: We try to make 'em
as realistic as possible.
The next time they see this
it would be in the real world.
NARRATOR: During the test,
veteran instructor,
Wissam, will be watching
the trainees' every move.
WISSAM: No visor down,
no visor down.
So why doing it the wrong way,
the wrong procedure?
NARRATOR: Wissam
will be judging the recruits on everything
they've learned so far.
From breathing apparatus
to hoses, and ladders.
WISSAM: Move.
You did it twice, and
two times you did wrong.
NARRATOR: He'll give the trainees
just 20 minutes to complete the
task or they fail.
WISSAM: They have to pass this
exercise, otherwise
they have to do the all the
course, the eight weeks again.
NARRATOR: The trainees need
to prove they're strong enough
to be professional firefighters.
Abdulrahman has already suffered
from heat exhaustion in a previous test.
WISSAM: OK?
ABDULRAHMAN (off-screen): I
felt like I'm going to faint.
I felt really dehydrated.
Feel like you're blacking out.
From the sides, it's getting darker.
NARRATOR: Today's fire will be even
hotter than anything he's faced before.
If he can't take the heat,
it's the end of the road.
ABDULRAHMAN: It's in my
head right now, what will happen inside.
If I fail, I'll be very,
very disappointed in myself.
WISSAM: So the firefighters
will be Abdulrahman.
NARRATOR: Wissam
divides Abdulrahman,
Yared and the others into two teams.
WISSAM: Yared. Rescue team.
NARRATOR: The firefighters
must control and extinguish the blaze,
and the rescue team must locate
and extract two life-size dummies.
WISSAM: Attention.
NARRATOR: All within a
strict 20 minute time limit.
WISSAM: Go.
NARRATOR: The test begins.
For Abdulrahman, the heat is on.
WISSAM: In the real life there is no
second chance to save people's lives.
They have to pass from the first time.
NARRATOR: At the cargo terminal,
head of customs inspection, Aref Alsaeedi,
has been called to the x-ray room.
Customs officers have been alerted
to a shipment of electrical goods with
something unexpected inside.
AREF: We have now one package
that's coming from Pakistan
will go to China.
It have two tennis balls.
OFFICER: It's very thick
and very low here.
Maybe like explosive things.
I don't know.
AREF: Our experience, poor
country like Pakistan
it's a high risk in the drugs.
NARRATOR: Dubai is a
major transit hub for cargo,
so customs are always
on the lookout for drugs.
Recently, Aref busted a drug
shipment going from Iran to Malaysia,
weighing in at 440 pounds.
So finding two tennis balls
in a shipment of electronics,
especially from a blacklisted
country like Pakistan,
immediately raises a red flag.
AREF: One is light.
One is heavy.
Drugs you can put anywhere.
NARRATOR: To check if there
are drugs inside the tennis balls,
Aref needs to investigate further.
But he can't damage the
balls without more evidence.
AREF: We are going
to call our dog unit
to check maybe drug inside or something.
Maybe, maybe yes, maybe no.
NARRATOR: There are over 35
dogs in the Dubai airport canine unit.
Handlers use different
dogs to hunt for a range of illicit items.
Drugs, explosives, currency
and even human remains.
Today they've brought
in the drug specialists.
AREF: For him it's
like type of game.
He is happy now.
NARRATOR: Aref must hide the box
of tennis balls among other shipments.
That way, the dog has to
actively sniff it out instead of just
confirming its presence.
AREF: The dog will go now
to check the shipment.
If found, will catch it,
if not found, will come back.
NARRATOR: If the dog can
sniff something suspect,
Aref will have the evidence he
needs to take this case further.
AREF: He found something!
NARRATOR: In the cargo bay
of an A380 fire simulator,
Abdulrahman must tackle an inferno.
ABDULRAHMAN: This will
be tougher than what we've done before.
NARRATOR: For him, it's a
personal test to see if he can handle
the soaring temperatures.
ABDULRAHMAN: The heat being
the most difficult thing.
Very hard for us.
NARRATOR: He's weighed down
by 50 pounds of breathing apparatus,
and high pressure hoses,
which eject two
gallons of water per second.
Supervisor Wissam is right beside
him, watching his every move.
WISSAM: OK,
firefighter, OK. Go.
NARRATOR: Abdulrahman has just 15 minutes
left of this final practical test and
he must quickly put out the fires before
Yared and the rescue team can do their job.
WISSAM: Move.
NARRATOR: Supervisor Chris
monitors their progress.
CHRIS: So far, so good.
The next step is now the rescue
team and how quickly they get the
two casualties out.
WISSAM: Mind your head.
NARRATOR: Yared
and his rescue team advance using a method
called shuffle and brush.
WISSAM: Grab that,
together, hands together.
NARRATOR: It's the best way for him to
locate the two dummies in poor visibility.
YARED (off-screen): There
is a fire plus the smoke.
It's hot.
You never know what to
expect in front of you.
That is a danger of this job.
NARRATOR: There are now 12 minutes
left for Yared to locate the dummies.
CHRIS: I haven't seen any dummies
taken to the front of the aircraft yet,
so that's a little bit worrying.
So, hopefully we'll see the rescue
team with a dummy any minute now.
NARRATOR: Two minutes later,
Yared has still not found any dummies.
And they're in danger
of running out of time.
NARRATOR: At the cargo terminal,
Aref's sniffer dog has alerted him
to signs of drugs.
AREF: To make sure, we'll
call other dogs now.
NARRATOR: A sniffer
dog's sense of smell can be over a million
times more sensitive than humans.
But even if both dogs
alert to the same package,
it's still not conclusive
proof that drugs are inside,
as they're also trained to detect
masking agents the traffickers use
to help avoid detection.
Instead of a bark, this
dog alerts by lying down.
AREF: The second dog also
give a signal there is drugs.
NARRATOR: With confirmation
from the second dog,
Aref will take this
case to the next level.
Now, he'll use chemical analysis.
AREF: Now we are going to check.
NARRATOR: One swab is enough for
this $50,000 mass spectrometry machine
to reveal even the tiniest trace of drugs.
AREF: I trust this machine.
It's 100% accurate.
NARRATOR: The
result is negative.
AREF: The machine says no drugs.
NARRATOR: With decades of experience,
Aref is still suspicious and there's only
one way to know for sure.
AREF: We have to
drill the ball
because you know, we have two dogs
to give the signal there is something.
To make sure.
NARRATOR: Because one ball
is heavier than the other,
he wants to check inside it.
(speaking in native language).
AREF: We saw something.
It's looking like, not sure, but it's
looking like heroin.
NARRATOR: If it is heroin,
a ball this size could contain
$40,000 worth of the drug.
AREF: We'll go to check this.
Can we check this please.
If there is a small,
small amount of drugs
at least will give a signal.
OFFICER: There's nothing.
AREF: Nothing?
OFFICER: Nothing.
NARRATOR: Aref now has
a conclusive result.
AREF: The powder is rubber.
Now sure 100%, no drugs.
We'll go to release the shipment.
The parcel will go to customer.
NARRATOR: This time
the package is clean.
But Aref is still
not convinced it's entirely harmless.
Traffickers often experiment
with what's known as cold runs,
to see whether customs
spot an unusual shipment.
AREF: Smugglers sometimes
they're going to test us
to see how is the security procedure here.
But in future we will be ready.
WISSAM: Again, fire, fire.
NARRATOR: Eight weeks of intensive
training all hang on the next few minutes.
As Abdulrahman and
Yared take on their final practical exam.
But on the rescue team,
Yared still hasn't been
able to find either of the two dummies and
he only has ten
minutes left before he runs out of time.
YARED: We have to shuffle,
go right, go left, go right, go left.
NARRATOR: In the real world,
the casualties could
be near death from heat and smoke by now.
The recruits must stay focused.
CHRIS: That heat is very contained in
there so they'll be dealing with all that,
not being able to see.
It can be very disorientating.
NARRATOR: They must be methodical
to make sure they don't miss anything
as they head deeper in to the cargo hold.
(whistling, shouting).
CHRIS: So the rescue team
have found the first casualty.
WISSAM: Hey, what
you are doing now?
CHRIS: And now they're
going back to try and find the second one.
WISSAM: Push, push, push.
NARRATOR: To help Yared find the
dummy fast, Abdulrahman must keep the
flames under control.
ABDULRAHMAN: You never know
when fire might come back on.
So if the rescue team has passed by and
the fire comes on, they might be in danger.
NARRATOR: There are just eight
minutes left on the clock.
CHRIS: They have
to do this quickly.
And not only that, they'll have the nerves
of knowing that this is an assessment,
and that they're being tested.
NARRATOR: At the furthest point
from the exit, Yared finds the dummy.
But the fire has blocked his retreat.
In this heat, his core temperature
can rise to 104 degrees
Beyond that, he's in danger of
heat stroke and even brain damage.
WISSAM: The rescue team
must quit the area.
NARRATOR: The fire is back
under control but all the trainees still
need to get out.
WISSAM: OK, you can move now.
MAN: OK, number three, go!
WISSAM: Always go back safe.
NARRATOR: The
test is finally over,
with minutes to spare.
ABDULRAHMAN: I feel
it went well.
The heat was obviously worse.
Maybe Wissam saw something wrong.
But in my view, so far we did well.
NARRATOR: Yared and Abdulrahman
are now just one step away from being
professional firefighters.
But nothing gets past eagle
eyed veteran trainer, Wissam.
WISSAM: OK guys.
You did the last exercise.
For some of you it was really difficult.
A firefighter's job is
a big responsibility.
Every day I learn more and more and more.
So this is only the
first steps in your firefighter's life.
(speaking in native language).
FIREFIGHTERS:
Oooh, we made it guys.
(laughter).
NARRATOR: The whole
team has passed.
After leaving their homes in Ethiopia and
Tanzania to take on this eight week course
this is a life changing
moment for Yared and Abdulrahman.
ABDULRAHMAN (off-screen):
It feels great.
I'm glad that we complete
the course successfully.
And all my team mates have passed as well.
YARED (off-screen): Ah, my
family will be very happy.
This is the best thing
that we have ever done.
Captioned by Cotter Captioning Services.