Date: 30th November 2024
Location: Vancouver International Airport, Canada
Aircraft: Boeing 767-300, registration C-FCJU
Operator: Cargojet
Flight Number: W8-2384
Route: Vancouver (BC) to Hamilton (ON), Canada
Occupants: 2 crew, 3 jump seaters
Injuries: None reported
Summary of Events
On 30th November 2024, Cargojet flight W8-2384, a Boeing 767-300 freighter, departed Vancouver en route to Hamilton when the crew experienced a compressor stall in the right-hand engine (PW4060) at around 10,000 feet during climb. The engine showed a significant rise in internal temperature, leading the crew to reduce it to idle thrust. Descending through 9,000 feet, the engine began to vibrate and produce loud noises, prompting the crew to shut it down. The aircraft entered a holding pattern at 9,000 feet for approximately two hours to burn fuel and reduce weight before landing safely back at Vancouver.
Maintenance inspections revealed metal debris in the engine exhaust, indicating internal engine failure. The engine is undergoing replacement.
Aircraft Information
The Boeing 767-300 is a wide-body freighter commonly used for long-haul cargo operations. The Pratt & Whitney PW4060 engines powering the aircraft are known for their reliability but can experience issues such as compressor stalls under specific conditions.
Sequence of Events
1. Climb-Out:
• After departing Vancouver, the aircraft climbed to 10,000 feet when the right-hand engine experienced a compressor stall accompanied by a sharp rise in internal temperature.
2. Engine Management:
• The crew reduced the affected engine to idle thrust to manage the situation.
3. Engine Shutdown:
• As the aircraft descended to 9,000 feet, the right-hand engine began to vibrate and emit loud noises. The crew subsequently shut the engine down to prevent further damage.
4. Fuel Burn and Landing:
• To avoid an overweight landing, the aircraft held at 9,000 feet for about two hours to burn off fuel.
• The aircraft made a safe landing at Vancouver International Airport.
5. Maintenance Actions:
• Post-flight inspections revealed metal fragments in the engine exhaust, confirming an internal engine failure.
Initial Findings
Compressor Stall and Overheating
• The compressor stall likely resulted from disrupted airflow within the engine, leading to surges and an uncontrolled temperature rise.
Metal Debris in Exhaust
• The discovery of metal in the exhaust suggests significant internal damage to the engine, likely involving turbine or compressor components.
Crew Actions
• The crew’s swift decision to reduce thrust, shut down the engine, and hold to burn fuel exemplifies adherence to standard procedures for managing in-flight engine failures.
Safety Risks
1. Engine Fire Risk:
• A significant compressor stall and overheating can lead to engine fire if not managed promptly.
2. Overweight Landing:
• Landing at an overweight condition poses risks to structural integrity and braking performance.
3. Loss of Redundancy:
• A single-engine operation increases reliance on the remaining engine, heightening operational risks in case of further issues.
Recommendations
1. Engine Inspections and Analysis:
• Conduct a thorough investigation of the failed engine to identify the root cause of the compressor stall and internal failure.
2. Maintenance Procedures:
• Review maintenance records and procedures to ensure compliance with engine service bulletins and preventive measures for similar engine models.
3. Crew Training:
• Reinforce training for engine failure scenarios, including fuel management and overweight landing protocols.
4. Fleet-Wide Checks:
• Examine other PW4060 engines in the fleet for signs of similar issues to mitigate risks.
Safety Lessons
This incident highlights the importance of robust engine maintenance practices and crew preparedness for managing critical situations. The crew’s decision-making and adherence to safety protocols ensured a successful outcome despite the challenges.
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Our investigation reports are based on all the evidence and facts available at the time of writing and posting. We apologise if any details are missed or are not fully accurate.
