Engine surge leads to long-haul flight on three engines

Casualties unknown • FR

A Boeing 747-200 experienced an engine surge and visible flames shortly after takeoff from Saint-Denis Gillot, resulting in an 11-hour flight to Paris on three engines.

What happened

On the night of October 25, 2004, a Boeing 747-236B, registration G-BDXE, operated by European Air Charter and chartered by Air Austral, took off from Saint-Denis Gillot airport. At an altitude of approximately 300 ft, the number 4 engine experienced a surge, characterized by loud thuds, a sudden loss of thrust, and a significant increase in Exhaust Gas Temperature (EGT). Passengers and cabin crew observed flames on the right side of the aircraft.

The flight crew implemented emergency procedures for engine fire, severe damage, or separation, leading to the shutdown of the number 4 engine. The crew decided to continue the flight toward Europe on three engines. Due to reduced performance, the aircraft was unable to reach its planned cruise altitude of FL 350, initially climbing only to FL 230. After a flight duration of 11 hours and 34 minutes—44 minutes longer than planned—the aircraft landed at Paris Charles de Gaulle with approximately 3.2 tonnes of fuel remaining.

The investigation

The BEA examined the aircraft's flight recorders (FDR and CVR) and the Quick Access Recorder (QAR). Investigators also interviewed the flight crew and cabin crew. The investigation included a technical examination of the number 4 engine and a study of the aircraft's fuel management during the flight. The investigation also looked into the crew's decision-making process regarding the diversion and the communication between the cabin crew and passengers during the incident.

Probable cause

The engine surge was caused by the failure of the thermal coating on the high-pressure compressor stage 2 casing, leading to material detachment.

Frequently asked questions

What happened in the 2004-10-25 Boeing B747-200 accident near FR?

A Boeing 747-200 experienced an engine surge and visible flames shortly after takeoff from Saint-Denis Gillot, resulting in an 11-hour flight to Paris on three engines.

What aircraft was involved and where did it happen?

The accident on 2004-10-25 involved a Boeing B747-200, at FR.

What was the probable cause of the accident?

The engine surge was caused by the failure of the thermal coating on the high-pressure compressor stage 2 casing, leading to material detachment.

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