What happened
On July 4, 2005, a Lockheed 1011-385-3, registration A6-BSM, operated by Star Jet and chartered by Olympic Airlines, was preparing for flight OA202 at Paris Charles de Gaulle. The flight experienced significant delays due to a malfunctioning cargo door, which required ground mechanics to manually force the mechanism. After a lengthy boarding process and a nearly five-hour delay, the aircraft departed at 16:17 UTC.
Shortly after the landing gear was retracted, the crew heard several loud bangs and observed a sharp increase in the Turbine Gas Temperature (TGT) on engine number 3, reaching 860 °C. Passengers in the right-side rows reported seeing flames trailing from the engine. The flight crew immediately initiated the severe engine damage procedure, shutting down engine number 3 to extinguish the flames. The aircraft performed a right-hand turn and returned to the airport, landing safely on runway 27L at 16:29 UTC.
The investigation
The BEA investigation focused on the mechanical failure of the engine and the broader operational context of the carrier. Investigators examined the engine components, the aircraft's maintenance history, and the regulatory oversight of the operator. The inquiry also scrutinized the complex administrative structure of Star Jet, which involved various national regulations and a recent change in operational status from Star Air (Sierra Leone) to Star Jet (UAE).
Findings
Technical analysis revealed that engine number 3 had suffered significant compressor surging. This was caused by a combination of worn compressor blades, damage from a foreign object passing through the intermediate and high-pressure compressor stages, and the specific aerodynamic stresses encountered during the takeoff phase.
The investigation also identified systemic failures in the operator's management. The aircraft was found to be in poor overall condition, and the operator lacked a proper documentary framework to ensure adequate maintenance tracking. Furthermore, the investigation highlighted significant gaps in international safety oversight, noting that the operator's various regulatory ties and the lack of available documentation made it difficult for authorities to monitor the safety of its operations effectively.