No fatalities

Uncontained Engine Failure During Takeoff Leads to Fire (N425EX)

Windsor Locks-Bradley, United States of AmericaTakeoff (climb)

On May 3, 1991, a Boeing 727-100 (registration N425EX) operated by Ryan International Airlines was involved in an aviation accident near Windsor Locks-Bradley, United States of America during takeoff. No fatalities were reported. Investigators recorded the probable cause as: A catastrophic and uncontained failure of the n°3 engine which resulted in a fuel fed fire. This summary draws on records from the Bureau of Aircraft Accidents Archives (B3A); 10 related events involving the same aircraft type or operator are linked below.

Sourcesthe Bureau of Aircraft Accidents Archives (B3A)Primary report: the U.S. National Transportation Safety Board (NTSB) historical archiveUpdated 2026-07-04Data APIEditorial standards
Boeing 727-100
Photo: Pete Macklin / CC BY-SA 2.0, via Wikimedia Commons

During takeoff roll, the flightcrew of N425EX heard a thump and observed erratic indications from engine n°3. The captain aborted takeoff and stopped on the runway. A fire ensued from a severed fuel line after an uncontained high-pressure compressor disk failure.

Accident Sequence

During the takeoff roll, the flightcrew of N425EX experienced a 'thump' that resounded through the airplane. Concurrently, they observed erratic engine indications from the n°3 engine. The captain aborted the takeoff and brought the airplane to a stop on the runway. After the airplane came to rest, the fire warning system activated on the n°3 engine. The crew attempted to extinguish the fire using the airplane's fire extinguishing system, but their efforts were unsuccessful.

Post-Accident Examination

The post-accident examination of the n°3 engine revealed that the high-pressure compressor disk had failed due to a fatigue crack that originated from a corrosion pit. The shrapnel from the disk penetrated the engine nacelle and severed the main fuel line for the engine. The released fuel ignited and burned into the fuselage, igniting the 12,600 lbs of cargo being transported (U.S. Mail).

Findings

The official probable cause of the accident was a catastrophic and uncontained failure of the n°3 engine, which resulted in a fuel fed fire.

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Frequently asked questions

What happened in the 3 May 1991 Boeing 727-100 accident near Windsor Locks-Bradley, United States of America?

During takeoff roll, the flightcrew of N425EX heard a thump and observed erratic indications from engine n°3. The captain aborted takeoff and stopped on the runway. A fire ensued from a severed fuel line after an uncontained high-pressure compressor disk failure.

Were there any fatalities in the 3 May 1991 Boeing 727-100 accident?

No fatalities were recorded in this accident.

What aircraft was involved and where did it happen?

The accident on 3 May 1991 involved a Boeing 727-100, registration N425EX, operated by Ryan International Airlines, at Windsor Locks-Bradley, United States of America.

What was the probable cause of the accident?

A catastrophic and uncontained failure of the n°3 engine which resulted in a fuel fed fire.