The Story of the Heroic Landing of Cathay Pacific Flight 780

On April 13, 2010, Cathay Pacific Flight 780 faced a crisis that would test the limits of human skill and engineering resilience. What began as a routine flight from Surabaya, Indonesia, to Hong Kong transformed into a high-stakes battle against failing engines and escalating danger. Pilots Malcolm Waters and David Hayhoe were thrust into a situation that left little room for error, yet their composure and expertise turned a potential disaster into a story of survival and heroism.

Cathay Pacific Flight 780 was operated by an Airbus A330-300, registered as B-HLL. Onboard the flight 309 passengers and 13 crew members. Let’s dig into the story.

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A Flight Marred by Technical Challenges

Flight 780 departed from stand 8 at Juanda International Airport at 08:24 local time (01:24 UTC) and ascended from runway 28. During the climb, both Rolls-Royce Trent 700 engines displayed irregular engine pressure ratio fluctuations. Engine 2 was particularly unstable, but the crew, finding all other engine parameters normal, decided to proceed.

At cruising altitude, the electronic centralized aircraft monitoring (ECAM) system signaled an “ENG 2 CTL SYS FAULT” error. After consulting maintenance, it was deemed safe to continue the flight. Yet, as the flight progressed, the fault reappeared, further testing the crew’s judgment. At 05:19 UTC, while descending towards Hong Kong, the situation worsened with an “ENG 1 CTL SYS FAULT” and “ENG 2 STALL” warning. Compressor stalls on both engines—the first on Engine 2 and later on Engine 1—signaled severe engine problems.

Photo by ***Civil Aviation Department***

“Mayday” Declared

As the flight neared Hong Kong, thrust control issues emerged. Engine 1 was stuck at 74% N1 (fan speed), and Engine 2 was reduced to idle. Despite these complications, the crew skillfully declared a “mayday” and managed to stabilize the descent.

At 05:43 UTC, the aircraft landed on runway 07L at a groundspeed of 426 km/h (265 mph), nearly double the usual touchdown speed. The extreme speed exceeded the tire ratings and flap-extension limits, causing the aircraft to bounce before slamming onto the runway. Despite the challenges, the pilots employed manual braking to halt the plane, as the thrust reverser on Engine 2 was non-operational.

Airport firefighters extinguished flames emanating from the landing gear, and an emergency evacuation followed. While 57 passengers sustained injuries during the evacuation, most were minor, with only one serious case reported.

Cathay Pacific Flight 780 — Photo by ***Civil Aviation Department***

Investigating the Cause

The aftermath drew global attention, leading to a detailed investigation by agencies including the Hong Kong Civil Aviation Department, Airbus, and Rolls-Royce. The probe uncovered contamination in the fuel system, with spherical polymer particles clogging critical components.

The contamination originated at Juanda International Airport, where improper procedures during pipeline renovations allowed salt water to infiltrate the fueling system. This salt water compromised filter monitors, releasing superabsorbent polymer particles into the aircraft’s fuel. These particles seized the main metering valves in both engines, freezing thrust outputs and causing the in-flight crisis.

Aircraft of Cathay Pacific Flight 780

The Airbus A330-300 involved, B-HLL, had served Cathay Pacific since November 1998. Configured to seat 311 passengers, it had a storied career, including a transfer to Dragonair in 2012 and a reconfiguration for 307 passengers. Tragically, its service ended in 2020, with its final flight to Pinal Airpark, Arizona, before being scrapped in November 2021.

Heroes behind Cathay Pacific Flight 780

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The remarkable skill of Captain Malcolm Waters and First Officer David Hayhoe prevented a potential catastrophe. With 12 and 3 years of experience at Cathay Pacific, respectively, the Australian pilots relied on their expertise to execute the daring landing. Their efforts earned them the prestigious Polaris Award from the International Federation of Air Line Pilots’ Associations in 2014, placing them alongside aviation heroes like Chesley Sullenberger and Jeffrey Skiles.