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IndiGo A320neo Engine Failure Linked to Maintenance Assembly Error

IndiGo A320neo Engine Failure Linked to Maintenance Assembly Error
Investigation Reveals Cause of Engine Failure
A recent safety investigation has identified a maintenance assembly error as the root cause of an in-flight failure involving a Pratt & Whitney PW1127G engine on an IndiGo Airbus A320neo. The incident, which occurred in February 2023, resulted in significant internal damage to the engine and has prompted increased scrutiny of engine reliability within the aviation industry.
The Indian Aircraft Accident Investigation Bureau (AAIB) released its final report detailing the event that took place on 5 February 2023. The aircraft, registered VT-ISE, was operating a scheduled flight from Amritsar to Kolkata when, at approximately 3,000 feet during climb, the flight crew heard a loud bang accompanied by multiple warnings indicating a failure of the port-side engine. Following established emergency protocols, the crew shut down the affected engine and safely returned to Amritsar.
Upon landing, IndiGo maintenance teams discovered extensive damage to engine number one, necessitating its replacement. Initial inspections identified damage to the low-pressure turbine (LPT) blades, while a comprehensive teardown revealed widespread harm throughout the engine core, including the high-pressure compressor stages 4 to 8, high-pressure turbine (HPT) stages 1 and 2, and LPT stages 1 to 3.
Maintenance Error and Its Implications
The AAIB investigation pinpointed the failure to the displacement of a wire seal in the HPT 2nd stage air seal. The report concluded that the wire seal had been incorrectly assembled during the engine’s last shop visit in August 2022. This misassembly caused the air seal to bulge out of its intended position. Subsequent thermal expansion further reduced clearance, resulting in the air seal striking the turbine intermediate case—a type of contact previously unrecorded. The compromised serviceability of the engine was identified as the primary factor contributing to the serious incident. At the time, the aircraft was carrying 125 passengers and six crew members.
This event has highlighted the critical importance of rigorous maintenance procedures and the potentially severe consequences of assembly errors. IndiGo was compelled to ground the aircraft until a replacement engine was installed, exposing operational vulnerabilities linked to maintenance shortcomings.
Industry Response and Market Impact
The incident has triggered heightened industry-wide attention to engine reliability and maintenance standards. IndiGo’s operational efficiency and customer confidence face potential challenges as a result. Competitors within the sector are responding by strengthening safety protocols and increasing the monitoring of engine performance to mitigate the risk of similar failures.
Moreover, the broader narrowbody engine market is experiencing repercussions, with operators grounding aircraft for additional inspections and corrective actions. Industry analysts suggest that this trend may influence operational strategies and market dynamics as airlines and manufacturers strive to restore confidence and uphold safety standards.
The AAIB’s findings underscore the extensive ramifications that maintenance errors can have, not only for individual operators but for the aviation industry at large.

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