Qantas A380 (VH-OQI) flew for almost a month with a tool left inside the engine

[RooFlyer]

Tool found in engine of Qantas A380 two months after the item was reported missing

The bit of plastic seems to have sat there quite happily behind the fan blades for over 50 cycles without causing any issues.

An investigation has been launched into the discovery of a small tool behind the fan blades of a Qantas A380 at Los Angeles Airport, more than two months after the item was reported missing.

The Australian Transport Safety Bureau is investigating what it called a “foreign object debris” event, involving an A380 with the registration VH-OQI.

According to the ATSB’s investigation brief, a tool was found behind the fan blades of the number one engine during a maintenance inspection on February 2, 2024.

“The tool was confirmed to be a compressor turning tool which had been identified as missing since December 6, 2023,” the ATSB said.

Flight records show VH-OQI conducted almost daily flights in the period from December 6 to February 2, apparently without incident.

A statement from Qantas said they were taking the matter “extremely seriously”.

 

[jrfsp]

that could have really put a spanner in the works

 

[DejaBrew]

that could have really put a spanner in the works

 

[bPeteb]

Hahahahahaha. I was scanning and thought this said flexible plastic stool and I thought how the hell did it even get in there!!

 

[Hvr]

that could have really put a spanner in the works

It would've been a real wrench if something went wrong.

 

[Captain Halliday]

It would've been a real wrench if something went wrong.

Especially if the shift hit the fan.

 

[jb747]

Especially if the shift hit the fan.

From what I can gather, it was already behind the fan. Presumably at the bottom, which would mean it was hung up on some fan stator blades. Now that would also be the easiest place to see it in a preflight if it was an inner engine, but if it was an outer engine, then they're mounted too high to see the base of the fan up close. The positive is that the loss of a couple of fan stator blades has very little effect, and doesn't cause the cascade of destruction you'll get from turbine blades. (I know this from having tested it on a CF6.) I guess we'll have to wait for the ATSB to tell us exactly where it was.

 

[Mattg]

The ATSB has released a report into a Qantas A380 (VH-OQI) that flew 34 times between 6 December 2023 and 1 January 2024 with a tuning tool inside the engine. The foreign object had been left there, and was later found, during scheduled maintenance at LAX. Luckily it did not damage the engine.

Tool left in A380 engine after maintenance inspection highlights importance of tool control | ATSB

www.atsb.gov.au

An A380 operated multiple flights with a tool inside one of its engines, after maintenance engineers did not commence the lost tool procedure prior to the aircraft being released to service, an ATSB investigation report details.

The 1.25 m long nylon tool, used to turn the engine’s intermediate‑pressure compressor during borescope inspections, was found wedged against the low-pressure compressor outlet guide vanes during a scheduled maintenance check at Los Angeles on 1 January 2024.

It was determined that that the tool had been left in the engine during previous scheduled maintenance in Los Angeles on 6 December 2023.

Between the two maintenance checks, the Qantas aircraft had flown 34 cycles, totalling 294 hours, with the tool in the engine. Although the tool was found to have been deformed by high energy airflow, there was no damage observed to the engine itself.

 

[jb747]

Well, there was a tool in charge for 15 years, so just following the example….

 

[serfty]

Well, there was a tool in charge for 15 years, so just following the example….

Some are more obvious ... although wedged against others.

 

[jpp42]

Here's a link to the ATSB summary page where you can also download the full report:

Foreign object debris event involving Airbus A380, VH-OQI, at Los Angeles International Airport, United States, on 1 January 2024 | ATSB

www.atsb.gov.au

 

[SeaWolf]

7:30 has done a follow up.

Qantas called out for process failures and 'cascade of errors' over 1.25m tool left in A380 engine

The safety regulator has lashed national carrier Qantas over a "cascade of errors" that saw a 1.25-metre tool left in an engine for 300 hours of flying time.

www.abc.net.au

The ATSB investigation found there was a litany of missed opportunities to address the problem – including flags raised and ignored by Qantas staff – which ultimately resulted in a regulation breach after several procedures were skipped.