Delta Airlines Boeing 767 Diverts to Prestwick After In-Flight Engine Shutdown

Edinburgh, Scotland – On February 10th, 2023, a Delta Airlines Boeing 767-300, registration N197DN, operating as flight DL-209 from Edinburgh, Scotland, to New York JFK, USA, encountered a significant in-flight emergency shortly after takeoff. The aircraft’s right-hand engine (Pratt & Whitney PW4060) emitted a series of loud bangs and visible flames as it climbed out of Edinburgh’s runway 24, prompting the flight crew to initiate an emergency procedure and divert to Glasgow Prestwick Airport.

Incident Overview

The aircraft had reached approximately 10,000 feet when the right-hand engine began to malfunction, producing a series of explosions and streaks of flames. In response, the crew initially set a course to return to Edinburgh but then decided to divert to Glasgow Prestwick Airport, where the aircraft landed safely on runway 30 about 30 minutes after departure. Upon landing, the aircraft taxied to the apron, and all passengers disembarked normally.

Following the incident, the aircraft remained grounded at Prestwick until February 22nd, 2023, before being ferried to Atlanta, Georgia, for further inspection and maintenance. The aircraft returned to service on March 3rd, 2023.

Investigation and Preliminary Findings

The UK’s Air Accidents Investigation Branch (AAIB) opened an investigation into the incident, initially reporting that the aircraft had suffered a contained engine failure and a subsequent fuel leak, which led to the diversion. A brief interim statement released by the AAIB on February 9th, 2024, noted that the engine failure caused significant vibrations and abnormal engine indications, compelling the crew to divert to Prestwick.

The AAIB’s final report, released on July 18th, 2024, provided a detailed analysis of the incident, concluding that the primary cause of the engine failure was the fracture of a high-pressure turbine blade due to fatigue cracking. The fatigue crack was likely initiated by a combination of hot corrosion and external contamination, which weakened the blade over time. The failure of this blade caused additional damage to five other blades, resulting in an engine imbalance that transmitted vibrations throughout the aircraft.

The engine vibrations were so severe that they caused a drain tube in the right fuel tank to fracture. This fracture led to fuel leaking from the right wing, which subsequently ignited during the flight. However, the flames extinguished before landing, and neither the crew nor the passengers were aware of the fire until after the aircraft had safely landed.

Crew Response and Safety Procedures

The AAIB’s report highlighted the actions of the flight crew during the emergency, noting that their decision to divert to Prestwick was prudent given the circumstances. The crew managed the overweight landing by following established procedures, including the use of flaps 25, autoland, and maximum autobrake, while coordinating with air traffic control to ensure emergency services were on standby upon arrival.

Despite the challenging situation, the flight crew remained composed and focused on safely landing the aircraft. However, the report noted that the crew did not immediately shut down the affected engine, choosing instead to operate it at reduced thrust based on procedural guidance for engine surges or stalls. This decision was later reviewed in light of the engine’s continued deterioration during the approach, underscoring the importance of adhering to engine shutdown procedures in similar situations.

The report also praised the effective communication between the flight crew and cabin crew, which ensured that passengers were rapidly disembarked once the fuel leak was discovered after landing. The presence of fuel near the hot brakes posed a significant fire risk, but swift action by airport fire services and assertive management by the cabin crew helped avert a more serious incident.

Manufacturer and Regulatory Response

In response to the incident, the aircraft manufacturer has initiated a project to improve the reliability of the design, specifically addressing the vulnerability of the drain tube to vibration-induced fractures. The Federal Aviation Administration (FAA) is reviewing the manufacturer’s findings to ensure that the aircraft continues to meet certification requirements for large transport aircraft.

The AAIB’s final report also included a Safety Recommendation to the FAA, emphasizing the need for a thorough review of the risk associated with failed drain tubes and the potential for catastrophic outcomes. This recommendation underscores the importance of ongoing vigilance and proactive measures to address emerging safety concerns in aviation.

Conclusion

The Delta Airlines flight DL-209 incident on February 10th, 2023, serves as a critical case study in managing in-flight emergencies, particularly those involving engine failures and subsequent fuel leaks. The successful outcome of this event, despite the significant challenges faced by the flight crew, highlights the effectiveness of established emergency procedures and the importance of clear communication between all parties involved.

As the aviation industry continues to learn from such incidents, the improvements made in response to this event will contribute to the ongoing efforts to enhance the safety and reliability of commercial air travel.