DHL Cargo Boeing 757 door opened in flight (no injuries)

Question

DHL Cargo Boeing 757 door opened in flight (no injuries)

Eufalconimorph (Computer)

(OP)

14 Feb 21 03:45

Quote (Avherald)

A DHL Air Boeing 757-200 freighter, registration G-DHKZ performing freight flight QY-126 from Leipzig to Frankfurt/Main (Germany), was in the initial climb out of Leipzig's runway 26L when the crew stopped the climb at about 5300 feet MSL due to the cargo door opening completely, several parts separated from the airframe and were distributed over the ground around the Schkopau coal power plant located about 10nm west of Leipzig Airport. The aircraft immediately positioned to return to Leipzig landing in opposite direction to departure. The aircraft touched down on runway 08R at 05:47L (04:47Z) about 15 minutes after departure and stopped on the runway about 1500 meters/4900 feet down the runway. The aircraft remained on the runway for about 40 minutes, then was moved to the apron. The aircraft sustained substantial damage.

The occurrence aircraft is still on the ground in Leipzig about 12 hours after landing back.

Germany's BFU confirmed a cargo door apparently opened in flight and dispatched investigators on site. The BFU reported nobody was injured and no freight was ejected from the aircraft. An investigation has been opened.

Not (yet) enough information to tell anything about why (or how) the cargo door opened. There *should* be indicators and warnings if the door isn't locked before takeoff, so those either failed (engineering and/or maintenance failure) or were ignored (process and human failure). Or the actual latches failed, which would be an engineering or maintenance failure. Not a good event no matter the cause.

JohnRBaker (Mechanical) · Answer 1 · 2021-02-14 06:52:02

The item you quoted states that the "aircraft sustained substantial damage". Now if this is a photo of the actual aircraft...

...I don't really see any damage. That being said, if the door opened to the extent shown in the above photo while in flight, I'm amazed that it was able to stay aloft at all, let alone land without serious incident.

John R. Baker, P.E. (ret)
EX-Product 'Evangelist'
Irvine, CA
Siemens PLM:
UG/NX Museum:

The secret of life is not finding someone to live with
It's finding someone you can't live without

JohnRBaker (Mechanical) · Answer 2 · 2021-02-14 06:54:40

Here's another photo supposedly of the same aircraft:

John R. Baker, P.E. (ret)
EX-Product 'Evangelist'
Irvine, CA
Siemens PLM:
UG/NX Museum:

The secret of life is not finding someone to live with
It's finding someone you can't live without

Alistair_Heaton (Mechanical) · Answer 3 · 2021-02-14 08:20:25

Its a mod freighter 2011 was when it was converted. 29 years old.

Can't see any skin wrinkles.

The 757 was the last proper old school Boeing and built like a brick poo house so it might fly again. Its a RR engine machine which are considered the GTI version of the 757 fleet.

LittleInch (Petroleum) · Answer 4 · 2021-02-14 10:25:33

Interesting piece here which indicated these doors are special items using corrosive hydraulic fluid.
https://kawakaviation.com/what-we-do/blue-sky-proj...
I suspect also that the door is now more open than it should be to the damage might be to the door frame

Remember - More details = better answers
Also: If you get a response it's polite to respond to it.

itsmoked (Electrical) · Answer 5 · 2021-02-14 12:48:03

That's not a door! It's just a vertical canard.

Keith Cress
kcress - http://www.flaminsystems.com

zeusfaber (Military) · Answer 6 · 2021-02-14 15:31:12

@LittleInch, I think the whole 757 system runs on Skydrol - not just the cargo doors. Second from the top of my list of hydraulic fluids I most hate.

A.

Alistair_Heaton (Mechanical) · Answer 7 · 2021-02-14 16:06:57

Skydrol is Satan's man juice. Most Boeings run on the stuff.

It will have bent the framing although no wrinkles .Luckily no cross wind with that foremast resitting the rudder.

Eufalconimorph (Computer) · Answer 8 · 2021-02-14 18:27:54

I suspect the "substantial damage" is to the door and related systems (frame, hinges, latches, etc). This photo of another 757 cargo conversion shows normal opening angle. The inner paneling of the door on the damaged aircraft appears to be missing, that might be the debris that was reported to have fallen off.

LittleInch (Petroleum) · Answer 9 · 2021-02-14 18:32:54

I thought that as well but the photo from my link looks like this.

Remember - More details = better answers
Also: If you get a response it's polite to respond to it.

Eufalconimorph (Computer) · Answer 10 · 2021-02-14 20:19:04

Good spot! Though there's still all the missing paneling from the door interior, even if the hinges aren't damaged. It might just be cosmetic, but I'd bet (given the quote about substantial damage) that the hinge/latch system was damaged. Not "debris pulled into an engine" damaged, but still not likely to be flight-worthy without repair.

dik (Structural) · Answer 11 · 2021-02-14 22:14:08

From the net...
"Not only is it flammable, but when inhaled it can cause bad problems in the lungs. Excessive skydrol exposure can also cause nervous system problems and eye problems. A little skydrol on the skin is an irritant, but a lot of skydrol inhaled, in eyes, etc is very dangerous and can lead to permanent injury."

Rather than think climate change and the corona virus as science, think of it as the wrath of God. Feel any better?

-Dik

1503-44 (Petroleum) · Answer 12 · 2021-02-14 23:53:11

With the weather in that area this week, I'll bet somebody really felt the draft.

waross (Electrical) · Answer 13 · 2021-02-15 02:45:03

Here's one loading.
That is all the door has to open to load cargo.
I suggest that any opening wider than that represents damage.

OOps.Retraction.
It seems as if some models do have extra high opening cargo doors.

Bill
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It's the LAW!

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DHL Cargo Boeing 757 door opened in flight (no injuries)