Abnormal engine indications - Boeing 767-338, VH-OGO, near Perth Airport, Western Australia, on 12 November 2010

On 12 November 2010, a Qantas Airways operated, Boeing Company 767-338 aircraft, registered VH-OGO, departed Perth Airport, Western Australia, on a scheduled passenger flight to Melbourne, Victoria. During climb the flight crew heard a popping sound followed by vibration from the left engine. The vibration decreased when the engine power lever was retarded to the flight idle position. The crew declared a PAN and requested a return to Perth. Air traffic control alerted emergency services who were in attendance when the aircraft landed.

An initial examination of the aircraft revealed pieces of metal in the engine tail pipe and damage to the low-pressure turbine (LPT) module. The engine was replaced, and the aircraft returned to service.

The engine manufacturer attributed the failure to the LPT stage 3 nozzle. A new nozzle design was released 19 January 2011. The current repair limits and repair procedures are also being re-evaluated by the manufacturer.

The aircraft operator advises that; as many engines have undergone their last full refurbishment before fleet retirement, the operator will replace the nozzles on an attrition basis. In the interim, the operator has introduced additional inspections for preservice bulleting 72-1354 LPT stage 3 nozzles that should detect any signs of air foil cracking well in advance of a potential operational event.