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Crash: Sun Way IL76 at Karachi on Nov 28th 2010, uncontained engine failure and engine fire

By Simon Hradecky, created Saturday, Nov 27th 2010 21:53Z, last updated Wednesday, Mar 8th 2017 17:21Z

The crash site (Photo: AP/APTN)
The crash site (Photo: AP/APTN)
A Sun Way Ilyushin IL-76 freighter, registration 4L-GNI performing freight flight MGC-4412 from Karachi (Pakistan) to Khartoum (Sudan) carrying 8 crew and 31 tons of relief supplies for the Sudan, crashed into buildings of the Naval Housing Scheme near Dalmia at approximately 01:50L (20:50Z Nov 27th) shortly after takeoff from Karachi's runway 25L at 01:48L (20:48Z Nov 27th) and burst into flames. All crew perished in the crash, 4 people on the ground were killed, numerous people on the ground received injuries. The airplane was destroyed and about 20 buildings were destroyed or severly damaged.

Witnesses on the ground reported one of the right hand engines on fire as the aircraft climbed out of Karachi Airport.

An amateur video shows the airplane on fire before it impacted ground.

A resident in a building adjacent to the crash site reported, that the airplane came down with little forward speed as if the airplane had stalled, evident by the short distance the wreckage was distributed along.

Pakistan's CAA confirmed the aircraft type as IL76. The tower controller saw the airplane on fire as it climbed out of Karachi. All 8 on board have perished in the crash, a number of workers on the ground are feared dead. In the evening of Nov 28th the CAA reported, 12 bodies have been recovered from the crash site, all 8 crew and 4 locals working at the building site. Recovery workers are still searching the debris and may find more bodies.

In the late evening of Nov 28th Pakistan's CAA confirmed the tailnumber of the aircraft as 4L-GNI. The airplane had taken off runway 25L and crashed less than 2 minutes after takeoff. The flight data recorders have not yet been found. The wreckage is distributed in a relatively confined area.

Karachi Police reported in the morning of Nov 28th 10 people have been killed in the crash including all crew and 2 people on the ground.

Karachi Rescue Authorities said at noon Nov 28th, they recovered 3 bodies that did not belong to the occupants of the aircraft.

Pakistan's Navy said, there was no loss of life on the ground. The airplane came down in the Naval colony near Dalmia, however only hit houses in construction.

Sun Way said, the IL-76 most likely suffered a bird strike upon departure and burst into flames before impacting ground while attempting to climb out. The airplane had been leased in by Sun Way (editorial note: pointing towards 4L-GNI) and had undergone a thorough technical examination two weeks ago, which established the airplane was in ideal condition. The crew had rested 18 hours prior to departure.

Sun Way are based in Georgia, ICAO identifier MGC, the airline started in February 2010. According to ATDB they operate one IL-76 registration 4L-MGC (standing Nov 27th 23:30Z). According to an insider source the airplanes 4L-GNI and 4L-MGM may have joined Sun Way. ATDB later updated their fleet list of Sun Way, now (Nov 28th 07:00Z) listing a total of 4 IL-76s: 4L-GLM (owned), 4L-GNI (leased in from Sakaviaservice), 4L-MGC (owned) as active and 4L-MGM as in conversion.

Informal information received from Russia and Georgia point towards 4L-GNI as the aircraft involved in the crash. A source at Karachi Airport confirmed the aircraft involved was 4L-GNI.


Metars:
OPKC 272200Z 03003KTS 6000 SKC 15/11 Q.1013 NOSIG
OPKC 272130Z 01004KTS 6000 SKC 15/11 Q.1013 NOSIG
OPKC 272100Z 02003KTS 6000 SKC 15/11 Q.1013 NOSIG
OPKC 272030Z 04003KTS 6000 SKC 16/12 Q.1013 NOSIG
OPKC 272000Z 05004KTS 6000 SKC 17/12 Q.1013 NOSIG
OPKC 271930Z 05004KTS 6000 SKC 17/12 Q.1013 NOSIG
OPKC 271900Z 06004KTS 6000 SKC 17/12 Q.1013 NOSIG
OPKC 271830Z 03005KTS 6000 SKC 18/13 Q1014 NOSIG
OPKC 271800Z 03004KTS 6000 SKC 18/13 Q1014 NOSIG

Overview of crash site in daylight (Photo: AP/Fareed Khan):
Overview of crash site in daylight (Photo: AP/Fareed Khan)

Detail Map (Graphics: AVH/Wikimapia):
Detail Map (Graphics: AVH/Wikimapia)

Map (Graphics: AVH/Google Earth):
Map (Graphics: AVH/Google Earth)



By Simon Hradecky, created Wednesday, Mar 8th 2017 17:13Z, last updated Wednesday, Mar 8th 2017 17:21Z

On Mar 8th 2017 Pakistan's Safety Investigation Board (SIB) released their final report concluding the probable cause of the crash were:

The cause of the occurrence was uncontained failure of the 2nd stage disk of LP compressor of Engine # 4 due to fatigue fracture which resulted in in-flight fire and damage to adjacent areas of right wing / flaps to an extent that flight could not be sustained.

- The use of mishap engine beyond its manufacturer�s assigned life without assessment and life enhancement by the manufacturer was the cause of its uncontained fatigue failure.

The SIB reported the aircraft departed Karachi with a takeoff mass of 197 tons including 74 tons of fuel and 30.5 tons of cargo, humanitarian aids (tents). The CG was at 30% MAC.

The captain (57, ATPL, 7,272 flight hours total, 5,502 hours on type) was assisted by a first officer (46, CPL, 2,220 hours total, unknown hours on type) and a navigator (49, Navigators License, 6,350 hours total, 4,800 hours on type).

The aircraft departed Karachi's runway 25L at 20:48Z, reached 460 feet AGL then descended again and disappeared from radar. No emergency message or information about the status on board was received by ATC. The aircraft impacted ground at N24.8942 E67.1068 about 2nm from the runway end at a heading of 070 degrees. All 6 crew and 2 support engineers on board of the aircraft as well as 3 people on the ground were killed in the crash, the aircraft as well as a number of houses under construction were destroyed.

Fragments of the #4 engine low pressure compressor were found 1900 meters (1.03nm) from the runway end, the #4 engine low pressure compressor second stage disk (error in the graphics provided) was found 2400 meters (1.3nm) past the runway end, both showed no signs of fire damage.

The SIB complained that they did not receive the complete log books of the aircraft, only a number of pages from the log books were provided.

The SIB reported that the aircraft had received a certificate of airworthiness by Georgia's Ministry of Regional Development and Infrastructure valid until May 15th 2011.

However, Ilyushin had limited the service life of the airframe to 20 years which expired on May 29th 2004.

The last periodic maintenance was conducted in Osh (Kyrgyzstan) on Nov 13th 2010.

Engine #4 had been manufactured on Dec 30th 1980 and had undergone three overhauls since. The initial useful life of the engine had been defined as 6500 flight hours and 3375 flight cycles, the engine had accumulated (since new) 6,055 flight hours and 2877 flight cycles, since last overhaul 1,209 flight hours in 451 flight cycles.

Engine #4 was also service limited by calendar on Oct 26th 2011.

Engine #4 has been removed from service in 2004 following the expiry of its initial service life. The SIB wrote referencing the engine manufacturer NPO Saturn:

The engine was put out of service on 1st May, 2004 after completion of its assigned life. The engine had completed 1638 / 6485 hours 501 / 2929 cycles at the time it was put out of service.

- NPO Saturn did not have any information about operation, maintenance and prolongation between-overhaul hours / cycle�s life or calendar service life after 1st May, 2004.

- The section 6.2 of the engine log book (resource, service life) had entries of betweenoverhaul life extended up to 26th October, 2010 and 26th October, 2011 referring �Technical Condition Reports� dated 20th May, 2010 and 19th July, 2010 respectively. However, �Technical Condition Reports�, NPO Saturn telegrams and records of log book section 12.2 were not made available by the operator.

- According to the information provided by the operator as on 13th November, 2010 this engine had between-overhaul remaining life of 444 hours / 496 cycles and its calendar service life were expiring on 20th October, 2011. The operator however, could not provide �Technical Condition Report� and NPO Saturn telegrams in support of service life extensions.

- Based on the available evidence it was established that at the time of the crash this engine (S No. 0304404011876) was being operated beyond the service life established by NPO Saturn.

The SIB analysed that on previous flights the crew had difficulties starting engine #4 and needed to shut the engine down again using the emergency stop valve, probably due to a hung start. Subsequently the air bleed for Inlet Guide Vane heating was opened for the restart of the engine. The SIB analysed that the cause of the abnormal starts most likely was wear of blades reducing the compressor efficiency.

The SIB analysed that for engine start for the accident flight engines #1, #2 and #3 were started, the crew opened the air bleed for inlet guide vane heading and started engine #4 without issue.

The aircraft commenced the takeoff run at 20:43:05Z, the crew rotated the aircraft for takeoff at 20:43:53Z at 274 kph (148 KIAS). The gear was retracted. At 20:44:27Z the aircraft was climbing through 90 meters/295 feet at 320 kph (173 KIAS), the crew just made a transmission but interrupted the transmission probably by a critical situation on board. Radio contact was lost afterwards.

At 20:44:30.5Z the high pressure rpm of the #4 engine suddenly ran down, a fire #4 engine indication as well as a fire indication on board occurred, the aircraft climbed through 100 meters/330 feet at 325kph (175 KIAS) about 2000 meters past the runway end. The other three engines continued to run normally on takeoff power. The aircraft banked to the right at about 8 to 9 degrees/second, ailerons and spoilers were deflected on maximum angles to compensate for the right hand roll, at the same time the crew applied left rudder pressure (-9 degrees of rudder position), the right hand roll stopped reaching a maximum of 14.7 degrees and reduced. Thrust lever engine #4 was reduced to idle, the engine was shut down using the emergency stop valve 11 seconds after the engine failure.

After 20:44:39Z the aircraft continued to roll right despite full left deflections of ailerons and spoilers and reached 32 degrees of right bank within the next 4 seconds. The climb stopped at 140 meters/460 feet AGL and the aircraft began to descend again, due the bank angle the radio altitude continued to increase. By 20:44:51Z the aircraft had reached 71 degrees of right bank and impacted ground at 20:44:53z.

The SIB reported that the fragment of the 2nd stage low pressure compressor disk was lost in the cause of the investigation, the failure analysis of the #4 engine was thus conducted based on the photographs that were made after recovery of the fragment (see below).

A fatigue crack had developed in the 2nd stage disk starting from the extreme edges of the hole of the disk, which is meant for installing the bushing for pin of compressor blades. There had been previous such failure scenarios as result of fretting corrosion in the holes for installing the bushings. This type of failure had been discovered in 1992 and remedial measures were mandated via 4 bulletins. All aircraft operating in the Russian federation were accordingly modified. However, due to the lack of documentation provided it could not be determined, whether the accident engine had undergone that modification.

The SIB analysed that a single engine failure could not have caused a scenario in which it was impossible to counter the yaw/roll tendency with the flight controls. Mathematic modelling showed however, that the accident aircraft's additional roll tendency might have been caused by damage to the flaps located right above and behind the engine causing the loss of lift on parts of the right hand wing. The effect observed on the accident aircraft could be produced by loss of 20% of the flaps.

Photos of the recovered - and lost - low pressure compressor 2nd stage disk (Photo: SIB):
Photos of the recovered - and lost - low pressure compressor 2nd stage disk (Photo: SIB)

Locations of the engines on the crash site (Photo: SIB):
Locations of the engines on the crash site (Photo: SIB)

Engine #4 fragment locations (Graphics: SIB):
Engine #4 fragment locations (Graphics: SIB)

Reader Comments: (the comments posted below do not reflect the view of The Aviation Herald but represent the view of the various posters)
@BOB
By Daniel H on Wednesday, May 16th 2012 07:38Z

In the event an investigation report is ever published on this tragic crash and Simon updates his site by reposting on the accident report, I would like to ask "Bob" what difference does it make if Nausheen practices Islam? What an innane and frankly out-of-place question to ask a fellow poster.

I don't believe Nausheen was for an instant equating the trash he saw on his TV and the aircraft's crash. He was merely pointing out what he was doing and thinking while doing it right before the crash, as people often do. No more. No less. He is right though, such crap should never be aired on channels or at times in which children may be able to see it. It shouldn't aired at all, IMO. But again, his comments were simple observational and situational comments. Your question, on the other hand, had less place here than anything he or anyone else had to say.


By Hasan on Thursday, Dec 2nd 2010 05:46Z

I heard there was a fuel leak.

Where is this video?
By bob on Tuesday, Nov 30th 2010 17:34Z

Does anyone have the link for the amateur video?

I don't think it was birds, more likey it was poor quality of engine manufacturer. The uncontainment of the engine likely took out fuel hoses, fire suppression controls, hydraulics, electrical systems, etc....which meant the crew had their hands full.

Nausheen, let me guess you practice islam?

May the crew and bystanders RIP.


By scepticus on Tuesday, Nov 30th 2010 13:31Z

Relief supplies? For the (cristian) south-sudan? wild birds fly at night for sure, even in IMC, for instance the black-necked crane.


By vagabond on Monday, Nov 29th 2010 16:34Z

Let me get this straight.The US gives Pakistan tons of relief for their floods and they give it to Sudan!

nature of cargo
By Alexander on Monday, Nov 29th 2010 11:27Z

they say : tents.. relief cargo..

Cargo?
By Kev the Rev on Monday, Nov 29th 2010 11:22Z

Any idea what the cargo was? This is pure speculation only.
Possibly overweight? CofG issue?

It is a Criminal Negligence,
By Khalid Baig on Monday, Nov 29th 2010 11:06Z

Please understand;

Aviation in itself is not inherently dangerous. It is terribly unforgiving of any carelessness, incapacity or neglect. Who so ever (or if any) is responsible for this neglect to Crash of IL-76 must be brought before the justice to stop this series of aircraft crashes in Pakistan and save innocent lives.

Procedures are there but no one bothers to follows;
Check the following link and read the ANO-15,

AIRWORTHINESS&MPage;=Airworthiness

Khalid

Birdstrike
By Sakeb on Monday, Nov 29th 2010 09:52Z

Wild birds do not have night vision equipment and hence don't fly at night. A bird strike at 1.50am sounds highly improbable. There are no owls in Karachi or any other large nocturnal birds for that matter.

Also 31~32 tons of payload to 2330 miles at this time of year should not require a takeoff at MTOW. I'm more curious to know why an engine fire could not be contained for 5 minutes to allow for an overweight return... Faulty sensors or fire suppression equipment anybody?

2 Ali and all ppl from Karachi
By Alexander on Monday, Nov 29th 2010 09:21Z

Guys , if there any birds flying around the karachi airport at ~ 02:00 am ?!.. because company owner says it was a birdstrike...



By Pavel on Sunday, Nov 28th 2010 22:38Z

Situation: max load, you need whole runway... your one engine has gone.. what will you do? If you try to stop it's crash(death)... if you try to take off...it's possible crash...but there is a chance....


By Pavel on Sunday, Nov 28th 2010 22:32Z

IL-76 can't climb on three engines if it is loaded as those post soviet pilot likes....

write "Close call!" to .. you will see....

@ ALI
By (anonymous) on Sunday, Nov 28th 2010 21:10Z

These stories arise every crash...sorry to tell you. When it comes down, it comes down, period.

The pilots are not trying to find a good place to die, they are trying to survive the situation

Sorry for the crew, airmen a a big family

@ ALI
By Nick on Sunday, Nov 28th 2010 19:27Z

Only one crewmember was russian, the other 7 were ukrainians.

RIP
By ALI on Sunday, Nov 28th 2010 18:02Z

I was standing in my office window when the plane took off and noticed that it had a slow rate of climb but then again I have seen these birds fully laden lifting off from the very edge of runway.i think ,full load of endurance fuel , 32 tons of cargo low level made a recovery impossible the aerodynamics and speed simply could not provide enough lift .Hats off to the wonderful pilot who chose to perish taking his plane into an small patch area where there were no lights assuming no populated houses were there..

RIP
By ALI on Sunday, Nov 28th 2010 18:00Z

I was standing in my office window when the plane took off and noticed that it had a slow rate of climb but then again I have seen these birds fully laden lifting off from the very edge of runway.As zain pointed ,even if there was an engines failure it could have climbed on 3 engines but i think ,full load of 8 hrs endurance fuel as well as 32 tons of cargo and extreme low level made a recovery impossible specially when it was trying to make a 180 turn back to airfield ,the aerodynamics and speed simply could not provide enough lift .Hats off to the wonderful pilot who chose to perish taking his plane into an small patch area where there were no lights assuming no populated houses were there.May the souls of all rest in peace and thier families have strength to bear this loss.BTW the crew were all russian not sudanese.

2paul
By kk on Sunday, Nov 28th 2010 17:57Z

On Ilyushin web page the 4L-GNI is not listed at all among planes that comply with the current ICAO and the International Aviation Committee requirements. It looks like something could be wrong with her maintance.


By dkclaymore on Sunday, Nov 28th 2010 12:11Z

R.I. P. for all perished.
Ilyushins are great machines, the conditions they work in are extreme,mostly none of the services we have in Europe or USA exist in their destinations. The idea of a ban on this type of aircraft would leave a large gap for the needing nations, I don`t think there is a suitable replacement for it yet...

Double Tragedy
By Mike on Sunday, Nov 28th 2010 08:48Z

Saddening to hear of this - lives lost and much needed foreign aid that won't reach it's destination, a double tragedy in all senses.

As far as the IL76 is concerned, don't these things operate in and out of locations that would make many seasoned four-wheel drive enthusiasts think twice? The vodka-burners seem to have spec's that cross them between an all terrain vehicle and an aircraft from what I can make out!

RIP to the crew and those on the ground

3 engines.
By Zain Maqsood on Sunday, Nov 28th 2010 06:46Z

If one of its engine got failed it could have leveled off and land back on 3 engines. May be they got into the panic.
Can engine failure affect the CG ?

@Steen
By Sakeb on Sunday, Nov 28th 2010 05:54Z

Good one man!

Nausheen, get a grip. This is an aviation reporting site. Start a blog somewhere for other things.

Act of God?
By Steen Petersen on Sunday, Nov 28th 2010 04:30Z

Nausheen, if this plane crash is indeed an act of some god as punishment for a tv show I wonder how this god set up the crash and why the god choose to do so instead of just stopping the tv show. Maybe investigation will show that the punishing god "fixed" an engine of the IL-76 some time ago when the decision to transmit the tv show was made?

As for the child watching the tv show it woudn't know that an "obscene" scene is wrong until told so by people like You. The question is, how hard would You - in the name of Your god off course - come down on the poor child for watching?

Anonymous
By PeterPan on Sunday, Nov 28th 2010 01:43Z

Well,now then, she`s MAINLY a strategic airlifter working in poor countries,landing on dirt strips most of the time,distributing aid more than often, and more than often overloaded as I think there are no scales in a lot of the poor countries she works in....
Furthermore, 964+ were built, including passenger versions, with 44 hull-losses costing 707 people lives...Iran airforce lost 1 in a crash with 275 Republican Guards-lives lost, making up the biggest portion of the 707.
Really no more un-safe than a lot of planes out there, if in fact not a better track record than most, so check out the facts first; flew on one 20 odd years ago;reckon the Soloviev`s are a bit underpowered, but otherwise a good solid Soviet bird...as they all are.

lack of maintenance
By paul on Sunday, Nov 28th 2010 00:51Z

The aircraft according to IL approved website still had not unfergone the life extension on the engines


Georgia IL-76"D 3008 4L-MGC 0023441189 20.07.2007 Service life procedure is under execution


By (anonymous) on Sunday, Nov 28th 2010 00:38Z

How many IL76 have crashed in the last 10 years? I cannot understand how they let all this operators still flying...an IL76 of a georgian carrier with african crew overflying a dense poblation area..the result will be in most cases a lot of burned bodies....if I woukd work in my country aviation authorities i would banish this airplane surely..

crew
By PeterPan on Sunday, Nov 28th 2010 00:22Z

Also saw on all the news reports the crew were not Sudanese but Russian?

@Simon?
By PeterPan on Sunday, Nov 28th 2010 00:20Z

One of the odd occasions where you trust ground witness reports as correct,Simon?
I saw on all the news reports everywhere,ground witnesses said one engine was on fire,but always thought, along with everyone else that that means nothing?

Sun Way
By Marc on Sunday, Nov 28th 2010 00:00Z

Hi,

The operator is called San Vai(Sun Way)from Georgia. 'Airlines' is not part of the name, ICAO code is MGC as stated.

They started operations in February 2010.

Marc



I Bet you mean (Silk Way airlines) !!
By Shadi Saeed on Saturday, Nov 27th 2010 23:55Z

There are no such airlines called Sun way if I'm not wrong.
there is either "Sunways Airlines" which they only have modern aircrafts and usually have no cargo special crafts.
The only logical airlines is the ((Silk Way)) which has a lot of the IL76-model aircrafts ...

I'm still confused and I'm not sure if what I've just said would make sense to you :)

Il-76 ;(
By Sergey on Saturday, Nov 27th 2010 23:34Z

RIP

Another 76's is gone forever :(

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