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April 11, 2004 · Mcdonnell Douglas DC-10-30 · N14075

Atlantic Ocean, AO

Overview

Report Status
Final with probable cause
Event Type
Accident
Date
April 11, 2004
Injury Outcomes
No injuries (252 uninjured)
Location
Atlantic Ocean, AO
Aircraft
Mcdonnell Douglas DC-10-30
Tail Number
N14075
Injuries
None
Aircraft Damage
Substantial
NTSB Number
NYC04TA103

During cruise flight, the crewmembers heard a "bang" from the rear of the cabin, and the airplane momentarily shuddered and bounced. After landing uneventfully at their destination airport, the crewmembers observed that the number two right engine cowling had separated and struck the right inboard elevator. Inspection of the airplane revealed that the engine cowling upper forward hinge required three bolts. However, only one bolt remained attached, and there was no evidence that the other two bolts tore away during flight. Fretting was observed in the area of the bolt holes, consistent with an oscillation over a period of time, due to the absence of two bolts. The airliner maintenance manual required a general inspection of the area, but did not specifically mention cowling hinge bolts. In addition, the hinges were located in an area that was not easily accessible to maintenance personnel.

NTSB Probable Cause

The failure of the number two upper forward right engine cowling attachment, which resulted in substantial damage to the right inboard elevator. A factor was the inadequate procedures in the airliner maintenance manual.

Full Narrative

On April 10, 2004, about 2258 eastern daylight time, a McDonnell Douglas DC-10-30, N14075, operated by World Airways Inc., as flight 725, was substantially damaged during cruise flight over the Atlantic Ocean. The 3 cockpit crewmembers, 9 cabin crewmembers, and 240 passengers were not injured. Night visual meteorological conditions prevailed for the flight that departed Naples, Italy; destined for Norfolk Naval Station (NGU), Norfolk, Virginia. An instrument flight rules flight plan was filed for the public use non-scheduled passenger flight. The captain reported that the airplane was in cruise flight at 32,000 feet. The airplane "shuddered and bounced" for a half-second, and then returned to stable flight. At that time, a flight attendant heard a "bang" from the rear of the airplane. The cockpit crew then felt a slight vibration, and noted a fuel burn of approximately 1,000 pounds per hour more than expected. However, all cockpit controls and instruments appeared normal. The flight proceeded to NGU and landed uneventfully about 0300, on April 11. A subsequent inspection of the airplane revealed that the right engine cowling had separated from the number two engine. Approximately 40 percent of the right inboard elevator had separated, consistent with the elevator being struck by the engine cowling. Further inspection of the airplane by a Federal Aviation Administration (FAA) investigator revealed that the engine cowling upper forward hinge required three bolts. However, only one bolt remained attached, and the investigator did not observe any evidence that the other two bolts tore away during flight. The investigator also noted fretting in the area of the bolt holes, consistent with an oscillation over a period of time, due to the absence of two bolts. The FAA investigator added that the airliner maintenance manual required a general inspection of the area, but did not specifically mention cowling hinge bolts. In addition, the hinges were located in an area that was not easily accessible to maintenance personnel. The investigator subsequently submitted a safety recommendation to have the cowling hinge bolts inspected every "D" check.

Flight

Event TypeAccident
Event Time02:58 UTC
Nearest Airport0nm
Flight Plan FiledIFR
Flight Plan ActivatedYes
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftMcdonnell Douglas DC-10-30
Tail NumberN14075
Aircraft CategoryAir
DamageSubstantial
Engines3
Engine TypeTurbofan
Engine DetailsGeneral Electric · CF6-50C2 · Turbofan · 53000 | General Electric · CF6-50C2 · Turbofan · 53000 | General Electric · CF6-50C2 · Turbofan · 53000
Seats377

People & Injuries

Injury SummaryNo injuries (252 uninjured)
Fatal0
Serious0
Minor0
Uninjured252
Total252
Crew 1Age 53 · First Class · None
Crew 2Age 41 · First Class · None

Conditions

ConditionsVMC
LightNight
Wind70° @ 6 kt
Visibility6 sm
CeilingBroken clouds 3000 ft
Temperature / Dew Point52 / 43 C
Altimeter30.01 inHg
Observation Time02:55
Weather SourceWFAC

Appendix: Source Data