An Airbus A380 operated by Qantas registered as VH-OQI, flew for nearly 300 hours across 34 flights with a tool left inside one of its engines, a situation that came to light after an investigation by the Australian Transport Safety Bureau (ATSB). The incident began on December 6, 2023, when the aircraft underwent routine maintenance at Los Angeles International Airport (LAX). Engineers conducting a borescope inspection of the left outboard engine's intermediate-pressure compressor inadvertently left a 1.25-meter nylon turning tool inside the engine.
.gif)
This oversight went unnoticed through subsequent pre-flight checks and the aircraft was released for service. The tool, intended for turning the engine's compressor during inspections, was found on January 1, 2024, during another scheduled maintenance check at LAX, after having remained in the engine for 26 days. Despite the tool being subjected to high-energy airflow, there was no reported damage to the engine itself, though the tool was found deformed.
The ATSB's report highlighted a significant lapse in maintaining tool control protocols. Maintenance engineers failed to initiate the lost tool procedure after realizing a tool was missing, and the aircraft was certified for flight without all tools accounted for. This incident prompted Qantas Engineering to take immediate action, briefing staff on the importance of ensuring all equipment is removed from the aircraft before flight. An internal investigation by Qantas led to the issuance of a safety directive focusing on strict adherence to tool control procedures.
Angus Mitchell, ATSB Chief Commissioner, emphasized the dangers posed by foreign object debris in aircraft engines, stating that such an event underscores the necessity for rigorous procedures and training to prevent foreign object damage. The incident, while not resulting in any mechanical failure or safety issues during flight, serves as a critical reminder of the importance of meticulous maintenance practices in aviation. Qantas has since reiterated its commitment to safety, stating that while there was no engine damage, the incident was taken extremely seriously. The airline's response included reinforcing internal processes to ensure all maintenance tools are accounted for before aircraft are cleared for operation.