Incident Overview
On an unspecified date, ValuJet Flight 597 began its takeoff roll when occupants heard a loud bang. The right engine fire warning light illuminated, and the crew of a following aircraft reported that the right engine was on fire. The takeoff was rejected. Shrapnel from the right engine penetrated the fuselage and the right engine main fuel line, causing a cabin fire to erupt. The airplane was brought to a stop on the runway, and the captain ordered an evacuation.
Injuries and Damage
One flight attendant sustained serious puncture wounds from shrapnel and thermal injuries. Another flight attendant and five passengers received minor injuries. The aircraft sustained damage from shrapnel penetration and fire.
Investigation Findings
The investigation determined that an uncontained failure of the right engine occurred due to fatigue failure of its 7th stage high compressor disc. The fatigue crack originated at a stress redistribution hole in the disc. Analysis of fatigue striation measurements indicated that the crack had developed before the disc was last overhauled at a repair station (Turk Hava Yollari) in 1991, but was not detected during that overhaul.
Repair Station Issues
Further investigation of the repair station revealed evidence of inadequate recordkeeping and a failure to use 'process sheets' to document step-by-step overhaul and inspection procedures. These deficiencies were noted as contributing factors to the undetected fatigue crack.
Reference
Additional information can be found in NTSB/AAR-96/03.