Date: 9th November 2024
Location: Luis Muñoz Marín International Airport, San Juan, Puerto Rico
Aircraft: Boeing 767-300, registration C-FXCA
Operator: Air Canada
Flight Number: AC-7220
Route: Atlanta, Georgia (USA), to San Juan, Puerto Rico
Crew: 2 (cargo flight)
Injuries: Both flight crew taken to hospital
Summary of Events
On 9th November 2024, Air Canada flight AC-7220, a Boeing 767-300 cargo flight, encountered smoke and odour in the cockpit during its final approach to San Juan’s Runway 10. The crew promptly donned oxygen masks, declared a MAYDAY, and landed the aircraft without further incident. Emergency services met the aircraft upon arrival, and both crew members were transported to a hospital for evaluation.
Initial maintenance inspections revealed a broken hydraulic line in the electronic bay as the likely cause of the smoke.
Aircraft and Maintenance Information
Aircraft
The Boeing 767-300 is a twin-engine wide-body aircraft frequently used for both passenger and cargo operations. Its hydraulic systems play a critical role in operating flight controls, landing gear, and other systems.
Maintenance History
• The aircraft had no prior history of hydraulic system malfunctions reported in recent inspections.
• Routine maintenance was last conducted two weeks before the incident, with no anomalies noted.
Sequence of Events
1. Approach to San Juan:
• During the final approach to Runway 10, the flight crew detected an odour in the cockpit, followed by the appearance of smoke.
2. Emergency Response:
• The smoke intensified, prompting the crew to immediately don oxygen masks and shut off the aircraft’s air conditioning packs to mitigate the situation.
• The crew declared a MAYDAY and prepared for an expedited landing.
3. Landing and Evacuation:
• The aircraft landed safely and was met by emergency services.
• Both pilots were evacuated and transported to a local hospital for medical evaluation.
4. Post-Landing Inspection:
• Maintenance personnel identified a broken hydraulic line in the electronic bay, which is believed to have caused the smoke and odour.
Investigation Findings
Root Cause
• Hydraulic Fluid Leak:
The failure of a hydraulic line in the electronic bay resulted in fluid leaking onto hot surfaces, producing smoke and odour in the cockpit.
Contributing Factors
1. Ageing Components:
• Hydraulic lines are subject to wear and tear, especially in older aircraft like the Boeing 767-300.
• The specific line involved had not been replaced during recent maintenance cycles.
2. Limited Early Warning:
• The odour and smoke were only detected during the final approach, leaving little time for preventive measures or troubleshooting.
Potential Risks and Consequences
1. Smoke in Critical Areas:
• Smoke in the cockpit poses a significant distraction and health risk to flight crews, impairing their ability to manage the flight effectively.
2. Hydraulic System Failures:
• A compromised hydraulic system can lead to reduced functionality of critical systems, including flight controls and landing gear.
3. Delayed Detection:
• The absence of earlier indications of hydraulic line failure highlights the need for enhanced monitoring and inspection protocols.
Recommendations
1. Enhanced Inspection Protocols:
• Introduce routine checks of hydraulic lines and fittings, particularly in high-risk areas like the electronic bay.
2. Component Replacement:
• Implement a proactive replacement program for ageing hydraulic components in older aircraft.
3. Smoke Mitigation Training:
• Reinforce training for flight crews to handle smoke and odour incidents, including rapid donning of oxygen masks and system isolation.
4. Improved Monitoring Systems:
• Equip aircraft with advanced sensors to detect hydraulic leaks and overheating components before they become critical.
5. Collaborative Investigations:
• Share findings with industry stakeholders to improve awareness and develop solutions for preventing similar incidents.
Safety Lessons and Industry Impact
This incident underscores the importance of maintaining and monitoring critical hydraulic systems, especially in older aircraft. The swift and professional response by the flight crew ensured a safe outcome, demonstrating the value of comprehensive emergency training. The findings are expected to inform future maintenance practices and operational protocols.
Disclaimer
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Our investigation reports are based on all the evidence and facts we have at the time of writing and posting. We apologise if any details are missed or are not fully accurate.
