Airbus A350 incident triggers extensive safety inspections – Aviation.Direct

A serious incident involving a Cathay Pacific Airbus A350-1000 has put the aviation industry on alert. On September 2, 2024, an engine fire broke out on the aircraft's second engine on a flight from Hong Kong to Zurich, requiring the aircraft to return to Hong Kong immediately.

The incident led to a fleet-wide inspection of 86 A350-1000 aircraft and may now also lead to investigations into the A350-900 series. A preliminary investigation by the Hong Kong Air Accident Investigation Authority (AAIA) and the European Aviation Safety Agency (EASA) has published initial findings that could have far-reaching consequences for the safety and maintenance of aircraft engines.

The incident: An engine fire forces an emergency landing

On September 2, 2024, just 75 minutes after Cathay Pacific flight CX383 took off for Zurich, the aircraft returned to Hong Kong due to an engine fire. The Airbus A350-1000, equipped with Rolls-Royce Trent XWB-97 engines, experienced a fire affecting the second engine. According to the AAIA's preliminary report, the fire was caused by a crack in the engine's steel-sheathed fuel hose. This resulted in a fuel leak, which in combination with oxygen and an ignition source (heat) triggered the fire.

The report details that several secondary fuel rail hoses were defective. Five additional hoses had either frayed metal strands or collapsed structures, indicating a possible weakness in the design or maintenance of the engines. These vulnerabilities could lead to significant safety risks if not addressed in a timely manner.

Fleet-wide inspections and airworthiness directives

Immediately after the incident, Cathay Pacific initiated a fleet-wide inspection of all Airbus A350-900s and A350-1000s in its fleet. In total, 48 of the airline's aircraft were inspected for possible similar issues. This measure was reinforced by pressure from European aviation authorities. The European Aviation Safety Agency (EASA) issued an updated airworthiness directive (AD) on September 19, 2024, which required the inspection of the A350-1000 fleet and could potentially affect some A350-900s as well.

The AD highlighted that a special cleaning procedure used during the overhaul of Trent XWB engines could be the main cause of the fuel hose damage. In particular, the Trent XWB-84, XWB-75, XWB-79 and XWB-79B engines, which are used in the A350-900, among others, could be affected by the questionable cleaning procedure. This procedure has now been discontinued and measures have been taken to ensure that similar incidents are avoided in the future.

Rolls-Royce under pressure: measures to secure the Trent XWB engines

Rolls-Royce, the manufacturer of the Trent XWB engines, now faces the challenge of ensuring the safety of its engines and regaining the trust of its customers. In a statement to Aviation Week, Rolls-Royce stressed that the company is working with EASA to carry out precautionary inspections of a small number of high-pressure fuel hoses in the affected engines. The prioritization of these inspections will be based on the service life of the engines and the frequency of maintenance visits.

The Trent XWB engines are one of the most modern and efficient engine ranges for long-haul aircraft such as the Airbus A350 range. However, the fact that they were potentially damaged by a cleaning process raises questions about the long-term reliability of this technology. Rolls-Royce has already taken steps to check those engines that have completed more than 18,500 engine flight hours since initial certification or have already had two or more workshop visits. These checks will also apply to engines that have reached 2,300 engine cycles.

Safety concerns and the importance of maintenance

The incident involving Cathay Pacific's Airbus A350-1000 has once again demonstrated the importance of regular and careful maintenance of aircraft engines. Modern engines are complex machines that operate under extreme conditions. Any weak point, whether in the design or maintenance, can have catastrophic consequences. Maintenance plays a crucial role, particularly in long-haul aircraft, where a high level of reliability and efficiency is essential.

Engine manufacturers such as Rolls-Royce invest significant resources in the development and maintenance of their products. However, the current incident shows that even small errors in maintenance or the manufacturing process can have far-reaching consequences. Aviation authorities worldwide have a responsibility to closely investigate such incidents and ensure that they do not happen again.

Consequences for other operators and Airbus?

The engine fire has forced not only Cathay Pacific but also other airlines to review their A350 fleets. Airbus' A350 range is considered one of the most modern long-haul aircraft on the market and many airlines rely on this model to operate international routes efficiently and in an environmentally friendly manner. However, the incident could affect confidence in the Trent XWB engines in the short term.

As more and more airlines equip their fleets with modern aircraft such as the A350, the long-term reliability of these aircraft is crucial. The long-haul aircraft market is highly competitive and airlines rely on reliable partners such as Rolls-Royce to maintain smooth operations.

A lesson for the aviation industry?

The Cathay Pacific engine fire is a serious incident that underlines the importance of preventive maintenance and rapid response measures in aviation. The airworthiness directives issued by EASA and the measures taken by Rolls-Royce to inspect the affected engines are steps in the right direction to ensure safety and maintain the confidence of airlines and passengers.

It remains to be seen what the final results of the ongoing investigation will be and what additional measures will be taken to prevent future incidents, but what is clear is that the aviation industry must remain constantly vigilant to ensure the safety of its passengers and crew.