An investigation by the Australian Transport Safety Bureau (ATSB) revealed that a Qantas Airbus A380 flew numerous flights with a tool left inside one of its engines. The tool, used during scheduled maintenance in December 2023, was discovered a month later in the engine during another routine check, raising important questions about safety procedures within the airline.
During a scheduled inspection on January 1, 2024, in Los Angeles, Qantas maintenance staff found a 1.25-meter nylon tool lodged against the low-pressure compressor outlet guide vanes in one of the A380’s engines. This tool, designed to rotate the engine’s intermediate-pressure compressor during borescope inspections, had remained in the engine for nearly a month. The previous maintenance inspection, which took place in Los Angeles on December 6, 2023, inadvertently left the tool inside the engine.
The plane continued to operate with the tool onboard for a total of 34 flight cycles, covering around 294 hours of flight time. Despite the intense airflow within the engine causing the tool to become deformed, the engine itself sustained no damage.
Investigation Findings and ATSB Statement
ATSB Chief Commissioner Angus Mitchell stated that maintenance engineers failed to identify the tool inside the low-pressure compressor case following the borescope inspection. “The ATSB investigation found that maintenance engineers did not notice the tool had been left in the engine’s low-pressure compressor case when conducting checks for foreign objects at the completion of the borescope inspection task,” he said. Mitchell explained that the engineers neglected to follow the lost tool procedure after realizing the tool was missing. Consequently, the aircraft was released for service without the tool being accounted for, raising concerns about adherence to established safety protocols.
Qantas Engineering promptly addressed the issue after the tool was found. The team briefed staff on the necessity of returning all tools to the tool store and ensuring compliance with tool control requirements. Qantas also conducted an internal investigation, resulting in a safety directive aimed at improving the enforcement of company tool control policies.
Importance of Tool Control and Safety Procedures
In response to the incident, Mitchell emphasized the vital role of tool control in aviation maintenance, especially in preventing foreign object debris from endangering flight safety. “Foreign object debris and damage can pose a serious threat to the safe operation of aircraft, which is why regulations, procedures, and training are in place to limit the risk of foreign object damage, particularly from introduced objects during maintenance,” he said. Mitchell added that following tool control protocols is essential in minimizing the risks associated with human error.
The release of the ATSB report follows another recent incident involving a Qantas aircraft. Last week, a Qantas plane experienced an engine failure shortly after taking off from Sydney Airport, forcing it to return and land safely. This contained engine failure reportedly led to a grassfire near the runway and caused several flight delays.
Qantas Chief Pilot Captain Richard Tobiano stated that Qantas flight QF520, en route to Brisbane, circled for a brief time before landing back in Sydney. Tobiano assured the public that “Qantas engineers have conducted a preliminary inspection of the engine and confirmed it was a contained engine failure.” He clarified that while passengers might have heard a loud bang, no explosion occurred.
