A Qantas Airways  Airbus A380-800, registration VH-OQC, operating as Flight QF-31 from Singapore Changi Airport (SIN) to London Heathrow Airport (LHR) was forced to make an emergency landing at Dubai International Airport (DXB) in the United Arab Emirates (UAE) on Friday, November 4, 2011 at 1:15 p.m. GST because of an engine problem, according to reports published on that date by The Daily Telegraph, The Guardian, The Malaysian Star, Reuters, Aviation Safety Network, AV Herald, and other news sources.

The flight crew had to shut down the number 4 outboard right hand Trent 972 engine, manufactured by Rolls-Royce,  due to an indication of low oil quantity.

The Airbus A380 jet with 258 passengers and 25 crew members, descended to 28,000 feet, and then was placed in a holding pattern at 10,000 feet for about one hour, before safely landing on the 14,583-foot Runway 30L, about 2-1/2 hours after the engine shutdown.

Last Friday’s incident occurred exactly one year after the midair blowout of a Trent 900 engine aboard Qantas Flight QF-32,  VH-OQA, on a trip from Singapore Changi Airport (SIN) to Kingsford Smith Airport (SYD) in Sydney, Australia.

That plane was forced to make an emergency return landing in Singapore, while showering debris onto houses and a shopping mall below the flight path in neighboring Indonesia.

The engine explosion also caused serious and multiple structural and mechanical damage to the aircraft.

An investigation by the Australian Transport Safety Bureau (ATSB) eventually traced the problem to a manufacturing defect in the Trent 900, which also occurred to other Airbus A380 aircraft that were operated by Singapore Airlines (SQ) and Lufthansa (LH).

Qantas is claiming that this most recent problem is “one-off” and “completely unrelated” to the engine blow-out last year that caused the entire Qantas fleet of Airbus A380-800 planes to be grounded.

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Rolls-Royce introduced the first of a two-phase performance improvement for the Trent 900 engines that power the Airbus A380 airliner. Turbofans now delivered to A380 operators have a 1-percent improvement in specific fuel consumption, compared with the initial units. Second-phase improvements due to enter service during 2013 will deliver a further 0.8-percent reduction in fuel burn.

In an October 21 press briefing, Trent 900 program director Rosie Toogood explained that all the improvements introduced focus on improving air flow and cooling of the engines. The first performance improvement package includes new elliptical leading edges (ELEs), tighter low-pressure tip clearance and a new hard coating for the high-pressure compressor drum. The second performance-improvement package, which is in its final stages, will cover the following elements: optimized fan blade tip clearance, better cooling of the turbine case, improved sealing for the low-pressure turbine, ELEs for the engine section stators, reprofiling of engine frames and upgrades to the air system.

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Europe’s air safety regulator has lifted the requirement for frequent, repetitive engine inspections of Rolls-Royce engines fitted to the Airbus A380 superjumbo, partly out of concern the inspections could now be doing more harm than good.

In the wake of the engine explosion under the wing of Qantas flight QF32 on November 4, the European Aviation Safety Agency required that Rolls-Royce Trent 900 engines fitted to Airbus A380s be inspected for oil leaks every 20 to 100 flights.

The relaxation comes despite Australian safety investigators launching new investigations into oil leaks in two Trent 900 engines on separate Qantas planes last month.

The oil leaks may have occurred because external oil pipes on two Trent 900s were done up improperly.

And the incidence of leaks has spread, with Singapore Airlines confirming it discovered five cases of oil leaks on the Rolls-Royce Trent 900 engines on its Airbus A380 planes.

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The Qantas Airbus A380 engine explosion that required a Sydney-bound jet to return to Singapore shortly after takeoff on Nov. 4 caused at least $70 million in plane damage, according to a report from insurance company Aon. 

The blowout of the A380′s Rolls-Royce engine will likely cost even more when factoring in extra repairs and inspections as well as costs associated with Qantas grounding its A380 fleet for most of this month, the AP reported.

Aon’s report comes as Australian authorities prepare to release its own study on the incident later this week. On the Nov. 4 flight, the A380 experienced engine problems not long after takeoff and returned to Singapore. None of the 440 passengers and 25 crew members were reported injured.

Qantas has said it will seek reimbursement from Rolls-Royce for some of the damages and costs stemming from the incident.

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Deliveries of the Airbus A380 superjumbo airliner will be cut this year from the planned 20 to 19, because of the failure of a Rolls Royce engine last month, company chairman Thomas Enders said on Wednesday.

On November 4, a Trent 900 engine made by Rolls-Royce of Britain and fitted on an A380 flown by Australian airline Qantas exploded in mid-flight causing serious damage to the aircraft.

Airbus has previously warned that the incident would affect deliveries owing to the time needed for inspections and replacements for the engine which powers aircraft used by three customers for the A380 — Qantas, Singapore Airlines and Lufthansa of Germany.

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Engine maker Rolls-Royce Group PLC on Friday said it would replace a component in Trent 900 engines following its investigation into the cause of an engine failure last week on an Airbus A380 aircraft.

 Rolls-Royce said its initial findings into the Nov. 4 incident on a plane operated by Qantas concluded that the issue was specific to the Trent 900 engine, as previously reported, and was confined to a particular component in the turbine area, which caused an oil fire that led to the release of the intermediate pressure turbine disc.

Situated at the back of an engine, the intermediate pressure turbine disc holds the blades of a turbine and rotates at high speed.

Rolls-Royce said it continued to work closely with investigating authorities and said its process of inspections would continue and would be supplemented by the replacement of the relevant module according to an agreed program.

Airbus Chief Executive Tom Enders said the problems with the Rolls-Royce Trent 900 engines would likely affect deliveries of new A380 planes next year because the British company would have to replace or modify engines.

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Tests uncovered oil stains in three Rolls-Royce engines on Singapore Airlines’ A380, prompting the airline to remove the planes from service Wednesday just two days after Qantas announced troubling oil leaks on its A380s.

The oil on the Qantas and Singapore planes was discovered during tests prompted by the explosion of a Rolls-Royce engine on a Qantas A380 during a flight from Singapore to Sydney last week. The plane made a safe emergency landing in Singapore, but the Australian airline immediately grounded its entire fleet of A380s while it investigated the cause.

Singapore Airlines said it does not know whether the oil stains found in its engines have any connection to the engine oil leaks found on Qantas, but was temporarily pulling the planes from service as a precaution. The planes, in Melbourne, Sydney and London, will be flown to Singapore without passengers, where they’ll be fitted with new engines.

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In a preliminary review suggestions have emerged that a spectacular engine failure near Singapore last week caused more damage to the plane involved than first thought.

The No 2 engine’s violent disintegration ripped a hole through the Airbus A380′s left wing, destroying wiring that prevented the pilots from turning off the No 1 engine and causing a fuel leak.  Suggestions have now emerged that there was also significant damage to hydraulic systems that prevented spoilers, panels on the wing that create drag to slow the plane down, from deploying.

The suggestions came as the Australian Transport Safety Bureau yesterday interviewed the flight crew of the stricken A380 and performed the first boroscope inspection of the Rolls-Royce Trent 900 engine.

Investigators are continuing their search for the rest of a turbine disc that broke up in the incident and have set up a schedule for examining a recovered piece that has been sent to Britain for forensic tests.

Rolls-Royce had a good understanding of the problem, which was likely to result in a series of recommendations.

The engine-maker broke its silence to say it had made progress in understanding the cause of the engine failure on QF32 but did not provide details.

Rolls-Royce rejected speculation there was a link between the Trent 900 failure and the uncontained failure of a Boeing 787 Trent 1000 engine operating “outside of normal parameters” on a test bed in Britain.

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Qantas believes the engine that blew apart on the world’s largest jetliner was probably designed or built incorrectly, the chief of the Australian airline said Friday, focusing attention on the engine’s manufacturer, Rolls-Royce.

On Thursday, one of Qantas’ six Airbus A380s suffered a massive engine failure in one of its four Rolls-Royce Trent 900 engines about four minutes into a flight to Sydney and shed pieces of metal over Indonesia before returning to make a safe emergency landing at Singapore’s airport.

“We believe this is probably most likely a material failure or some type of design issue,” Joyce told a news conference in Sydney. “We don’t believe this is related to maintenance in any way.” He said the engines had been maintained by Rolls-Royce since they were installed.

Ironically, hours after CEO Alan Joyce spoke, another Qantas plane with Rolls-Royce engines suffered an engine problem and turned back to Singapore’s airport shortly after it took off for Sydney. Qantas said the problem with the smaller Boeing 747 was not serious and the flight was scheduled to take off again, 3.5 hours late.

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