An ATSB investigation into a Boeing 737 engine failure during take-off from Sydney has recognised the contribution that effective training and procedures made towards a safe outcome.
On 8 November 2024, the Qantas 737-800, powered by two CFM International CFM56-7B turbofan engines, was taking off for a passenger flight to Brisbane.
During the take-off roll the flight crew heard a loud bang, accompanied by a shudder, as the right engine failed.
The flight crew immediately recognised the engine failure based on caution lights and indications, but continued the take-off, as the aircraft had reached the pre-calculated V1 decision speed beyond which a take-off should not be aborted.
“This engine failure occurred at the worst possible moment during a critical phase of flight,” ATSB Chief Commissioner Angus Mitchell said.
“The flight crew responded quickly and decisively, continuing the take-off, declaring an emergency, and conducting relevant checklists while planning a return to Sydney.”
The flight and cabin crew had an off-duty pilot photograph the engine and wing from the cabin, with no visible damage to the engine exterior or wing identified. About 30 minutes after taking off from runway 34R, the flight crew performed a single-engine landing on runway 34L.
After the engine was externally assessed for fire risk by Aviation Rescue Fire Fighting Service (ARFFS) personnel, the flight crew taxied back to the gate, where passengers were disembarked safely.
ARFFS had also responded to a grass fire which ignited alongside runway 34R from hot fragments expelled from the rear of the engine when the failure occurred.
Mr Mitchell said all parties involved in the emergency – the flight and cabin crew, ARFFS, and air traffic controllers – worked together effectively to ensure a safe and uneventful return to Sydney for the aircraft, and the 181 people on board.
“This incident provides a positive example of effective training and procedures, highlighting their importance within the aviation safety framework,” Mr Mitchell said.
“In particular, faced with an emergency during a critical phase of flight, the flight crew responded decisively and appropriately in accordance with their training and procedures.”
The ATSB’s investigation notes the engine failed due to one of its high-pressure turbine blades separating from the disc due to a fatigue crack.
The failure occurred 13 days before the engine was scheduled for removal, as it was approaching the threshold recommended by the manufacturer, CFM International.
Following this incident, CFM International performed an analysis of the CFM56-7B engine fleet and found that although there had been several previous engine failures due to this kind of fatigue cracking, the specific high-pressure turbine blade configuration of this engine still met internal reliability targets and relevant regulatory guidelines.
In addition, the final report notes, newer high-pressure turbine blade configurations have been introduced with improved failure rates.
Read the final report: Engine failure involving Boeing 737, VH-VYH, at Sydney Airport, New South Wales, on 8 November 2024