On 5 January 2024, a Boeing 737-9 which had just departed Portland was climbing through 14,800 feet when there was a loud bang followed by a rapid decompression. This resulted from the loss of a fuselage plug incorrectly installed at an unused door location during completion of the airframe manufacturing process. An emergency was declared and a landing back at Portland was made after a total of twenty minutes airborne. The investigation found that the fuselage plug involved was installed without being properly secured and identified deficiencies in the manufacturer's quality assurance processes as well as in the regulatory oversight.
Description
On 5 January 2024, a Boeing 737-9 (N704AL) which had only recently been delivered to Alaska Airlines was used on a scheduled domestic passenger flight from Portland to Ontario CA as AS1282. It was climbing through 14,800 feet in day visual conditions (VMC) six minutes after takeoff when a loud bang was followed by a rapid decompression. The immediate cause was the appearance of a door-sized opening in the rear cabin. The crew declared an emergency and the flight landed back at Portland fourteen minutes later. No passengers were immediately adjacent to the opening, and the injuries to seven passengers and one of the cabin crew in the vicinity were minor. Minor internal damage occurred to the passenger cabin in the immediate vicinity of the opening. The piece of detached fuselage structure was found in the back yard of a private house in Beaverton and recovered for examination, but most of the associated bolts and fittings were not found.
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