Additional Participating Entities:
Federal Aviation Administration / Flight Standards District Office; Greensboro, North Carolina
Continental Motors Inc; Mobile, Alabama
Aviation Accident Final Report - National Transportation Safety Board: https://app.ntsb.gov/pdf
Investigation Docket - National Transportation Safety Board: https://dms.ntsb.gov/pubdms
Aviation Accident Data Summary - National Transportation Safety Board: https://app.ntsb.gov/pdf
http://registry.faa.gov/N3241N
Location: Fayetteville, NC
Accident Number: ERA16LA066
Date & Time: 12/11/2015, 1931 EST
Registration: N3241N
Aircraft: RAYTHEON AIRCRAFT COMPANY A36
Aircraft Damage: Substantial
Defining Event: Powerplant sys/comp malf/fail
Injuries: 1 Serious, 3 Minor
Flight Conducted Under: Part 91: General Aviation - Personal
Analysis
During a cross-country flight at night, the airplane experienced a total loss of engine power. The private pilot's attempts to restart the engine were unsuccessful. The pilot attempted to glide the airplane to a diversionary airport, but when he realized the airplane would not reach the airport, he conducted a forced landing into wooded terrain.
Teardown examination of the engine revealed that the No. 1 cylinder and No. 3 connecting rod had fractured. Metallurgical examination revealed that there was a gray rubbery substance on the case halves, through bolts, and main bearing saddle faces, which could have restricted oil flow. The engine manufacturer's overhaul manual and a service bulletin and service information letter (SIL) listed only one approved sealant for use between case halves, which was similar in color and texture to grape jelly not to the rubbery gray sealant found in the engine, which was not an approved sealant. Further, the SIL stated that the use of an incorrect sealant "on mating threads and between mating surfaces can cause incorrect torque application and subsequent engine damage or failure."
Further, the No. 3 connecting rod journal exhibited heat damage and deformation, and the No. 3 connecting rod fracture was consistent with a lack of lubrication. Additionally, the No. 4 main bearing saddle boss exhibited fretting damage, consistent with bearing shift due to lack of torque on the through bolts and blockage of its oil port, which also would have restricted oil flow.
Review of maintenance records revealed that the engine was overhauled about 20 months before the accident. The engine had been operated for about 300 hours during that time. It is likely that maintenance personnel applied the unapproved sealant to the engine case halves during the engine overhaul, which ultimately resulted in the total loss of engine power.
Probable Cause and Findings
The National Transportation Safety Board determines the probable cause(s) of this accident to be:
Maintenance personnel's application of an unapproved sealant to the engine case halves during engine overhaul, contrary to manufacturer's instructions, which resulted in lubrication restriction due to a bearing shift and the subsequent internal failure of the engine due to the loss of case through-bolt torque.
Findings
Aircraft
Maintenance/inspections - Incorrect service/maintenance (Cause)
Oil - Fluid level (Cause)
Personnel issues
Unauthorized maint/repair - Maintenance personnel (Cause)
Use of policy/procedure - Maintenance personnel (Cause)
Factual Information
On December 11, 2015, at 1931 eastern standard time, a Beechcraft A36, N3241N, was substantially damaged during a forced landing to a wooded area after a total loss of engine power near Fayetteville, North Carolina. The private pilot and two passengers received minor injuries, and one passenger received serious injuries. Nighttime visual meteorological conditions prevailed and an instrument flight rules flight plan was filed. The personal flight departed Bay Bridge Airport (W29), Stevensville, Maryland about 1730 destined for Charleston Executive Airport (JZI), Charleston, South Carolina. The airplane was operated by the private pilot under the provisions of Title 14 Code of Federal Regulations Part 91.
According to the pilot, about 2 hours after takeoff the airplane was in cruise flight at 8,000 feet when the engine suddenly lost power. Engine power was restored for a few seconds, and then the airplane lost engine power again as the propeller "windmilled." The pilot turned the airplane toward Fayetteville Regional Airport (FAY) for a forced landing, and the propeller stopped turning during the descent. Attempts to restart the engine were unsuccessful. As the airplane approached FAY, the pilot determined that he was below the visual approach slope indicator lighting glidepath and that the airplane would not reach the airport and performed a forced landing to wooded terrain.
Examination of the wreckage at the accident site by a Federal Aviation Administration (FAA) inspector revealed that the airplane came to rest upright on the floor of a pine forest area. The engine and mounts separated from the firewall. The left wing was crushed and curled upward from about mid-span to the wing tip. A portion of the right wing was separated outboard of the flap and was located in the debris path about 25 yards prior to the main wreckage. The landing gear and flaps were found in the retracted position.
The airframe and engine were subsequently examined at a recovery facility under the supervision of a National Transportation Safety Board (NTSB) investigator. Fuel was present in both main tanks and both tip tanks, the fuel selector valve functioned normally, and the auxiliary pump switch was in the on position. Teardown examination of the engine revealed metal fragments from the No. 1 cylinder in the oil sump and internal damage including one connecting rod separated from the crankshaft, and two other connecting rods exhibiting discoloration consistent with heat damage. Additionally, a gray colored rubbery substance was observed on the mating surfaces of the crankcase halves. Engine components were forwarded to the NTSB Materials Laboratory, Washington, DC, for further examination. Metallurgical examination revealed beads of gray sealant on the through bolts and on the main bearing saddle faces, which can restrict oil flow. The No. 3 connecting rod journal exhibited heat damage and deformation and the No. 3 connecting rod was fractured, consistent with a lack of lubrication. Additionally, the No. 4 main bearing saddle boss exhibited fretting damage, consistent with bearing shift and blockage of its oil port, restricting oil flow.
Review of maintenance records revealed that the airplane's most recent annual inspection was completed on October 15, 2015. At that time, the engine had accumulated 300.6 hours since major overhaul. The engine was overhauled by Aero Engines of Winchester, Inc. on April 21, 2014.
Teledyne Continental Motors (TCM) Service Information Letter (SIL)99-2B, published October 17, 2005, related to current authorized sealants, lubricants, and adhesives. The SIL did not list any sealant on the mating surfaces of the crankcase halves except Gasket Maker P/N 646942 – or Loctite 515 Gasket Eliminator Sealant (or its predecessor, Permatex Aviation Grade 3D). Additionally, review of the overhaul manual revealed instructions to apply only TCM Sealant P/N 654663, which was Loctite 515, and silk thread P/N 641543 to the crankcase halves.
According to the Manager of Air Safety at Continental Motors Inc., the gray rubber sealant found in the engine was not consistent with Loctite 515, which appears in color and texture like grape jelly.
Additionally, review of TCM Service Bulletin (SB)96-7C, published February 8, 2005, which related to torque values for fasteners on all TCM engines, stated: "WARNING THE USE OF SEALANTS OR LUBRICANTS OTHER THAN THOSE SPECIFIED BY TCM ON MATING THREADS AND BETWEEN MATING SURFACES CAN CAUSE INCORRECT TORQUE APPLICATION AND SUBSEQUENT ENGINE DAMAGE OR FAILURE."
The FAA Subsequently published Special Airworthiness Information Bulletin (SAIB) NE-16-13, "Powerplant – Prohibited use of sealant" on March 8, 2016. According to the FAA principle maintenance inspector of Aero Engines LLC. (formerly Aero Engines of Winchester, Inc.), he performed a compliance action after the accident for Aero Engines to use only the specific sealant part number and product name (not MIL-SPEC [military standard]) specified by the engine manufacturer when overhauling their respective make and model engine. Additionally, Aero Engines reviewed all their overhauls for unapproved sealants and did not find any other subsequent cases. As of the publication of this report, there have been no further similar engine failures that were overhauled by Aero Engines. There was one previous case (NTSB ID No. ERA14FA313) of a similar failure of an engine overhauled by Aero Engines.
History of Flight
Enroute-cruise
Powerplant sys/comp malf/fail (Defining event)
Loss of engine power (total)
Attempted remediation/recovery
Emergency descent
Off-field or emergency landing
Pilot Information
Certificate: Private
Age: 46, Male
Airplane Rating(s): Single-engine Land
Seat Occupied: Left
Other Aircraft Rating(s): None
Restraint Used: 3-point
Instrument Rating(s): Airplane
Second Pilot Present: No
Instructor Rating(s): None
Toxicology Performed: No
Medical Certification: Class 3 Without Waivers/Limitations
Last FAA Medical Exam: 12/04/2013
Occupational Pilot: No
Last Flight Review or Equivalent:
Flight Time: 538 hours (Total, all aircraft), 245 hours (Total, this make and model), 502 hours (Pilot In Command, all aircraft), 20 hours (Last 90 days, all aircraft), 7 hours (Last 30 days, all aircraft), 3 hours (Last 24 hours, all aircraft)
Aircraft and Owner/Operator Information
Aircraft Make: RAYTHEON AIRCRAFT COMPANY
Registration: N3241N
Model/Series: A36
Aircraft Category: Airplane
Year of Manufacture: 1999
Amateur Built: No
Airworthiness Certificate: Utility
Serial Number: E-3241
Landing Gear Type: Retractable - Tricycle
Seats: 6
Date/Type of Last Inspection: 10/15/2015, 100 Hour
Certified Max Gross Wt.: 3651 lbs
Time Since Last Inspection: 39 Hours
Engines: 1 Reciprocating
Airframe Total Time: 1736 Hours at time of accident
Engine Manufacturer: Continental
ELT: C126 installed, activated, did not aid in locating accident
Engine Model/Series: IO-550-B
Registered Owner: ACES AVIATION LLC
Rated Power: 300 hp
Operator: On file
Operating Certificate(s) Held: None
Meteorological Information and Flight Plan
Conditions at Accident Site: Visual Conditions
Condition of Light: Night
Observation Facility, Elevation: FAY, 189 ft msl
Distance from Accident Site: 3 Nautical Miles
Observation Time: 1953 EST
Direction from Accident Site: 270°
Lowest Cloud Condition: Clear
Visibility: 10 Miles
Lowest Ceiling: None
Visibility (RVR):
Wind Speed/Gusts: 6 knots /
Turbulence Type Forecast/Actual: / None
Wind Direction: 220°
Turbulence Severity Forecast/Actual: / N/A
Altimeter Setting: 30.09 inches Hg
Temperature/Dew Point: 16°C / 14°C
Precipitation and Obscuration: No Obscuration; No Precipitation
Departure Point: STEVENSVILLE, MD (W29)
Type of Flight Plan Filed: IFR
Destination: CHARLESTON, SC (JZI)
Type of Clearance: IFR
Departure Time: 1730 EST
Type of Airspace: Class C; Class E
Wreckage and Impact Information
Crew Injuries: 1 Minor
Aircraft Damage: Substantial
Passenger Injuries: 1 Serious, 2 Minor
Aircraft Fire: None
Ground Injuries: N/A
Aircraft Explosion: None
Total Injuries: 1 Serious, 3 Minor
Latitude, Longitude: 34.990000, -78.829722 (est)
NTSB Identification: ERA16LA066
14 CFR Part 91: General Aviation
Accident occurred Friday, December 11, 2015 in Fayetteville, NC
Aircraft: RAYTHEON AIRCRAFT COMPANY A36, registration: N3241N
Injuries: 1 Serious, 3 Minor.
This is preliminary information, subject to change, and may contain errors. Any errors in this report will be corrected when the final report has been completed. NTSB investigators may not have traveled in support of this investigation and used data provided by various sources to prepare this aircraft accident report.
On December 11, 2015, at 1931 eastern standard time, a Beechcraft A36, N3241N, was substantially damaged during a forced landing to a wooded area after a total loss of engine power near Fayetteville, North Carolina. The instrument rated private pilot and two passengers received minor injuries, and one passenger received serious injuries. Nighttime visual meteorological conditions prevailed and an Instrument Flight Rules flight plan was filed. The personal flight departed Bay Bridge Airport (W29), Stevensville, Maryland about 1730 destined for Charleston Executive Airport (JZI), Charleston, South Carolina. The airplane was operated by a private individual under the provisions of Title 14 Code of Federal Regulations Part 91.
According to the pilot, about two hours after takeoff the airplane was in cruise flight at 8000 feet when the engine suddenly lost power. Engine power was restored for a few seconds, and then the airplane experienced a total loss of engine power as the propeller "windmilled."
The pilot turned the airplane toward Fayetteville Regional Airport (FAY) for the forced landing, and the propeller stopped turning during the descent. Attempts to restart the engine were unsuccessful.
As the airplane approached FAY, the pilot determined that he was below the Visual Approach Slope Indicator lighting glidepath and that the airplane would not reach the airport and performed a forced landing to wooded terrain.
Examination of the wreckage at the scene by a Federal Aviation Administration (FAA) inspector revealed that the airplane came to rest upright on the floor of a pine forest area. The engine and mounts separated from the firewall. The left wing was crushed and curled upward from about mid-span to the wing tip. A portion of the right wing was separated outboard of the flap and was located in the debris path about 25 yards prior to the main wreckage. The landing gear and flaps were found in the up position.
The airplane and engine were subsequently examined at a recovery facility under the supervision of an NTSB investigator. Fuel was present in both main tanks and both tip tanks, the fuel selector valve functioned normally, and the auxiliary pump switch was in the on position. Examination of the engine revealed metal fragments in the oil pan and internal damage including one connecting rod separated from the crankshaft, and two other connecting rods exhibiting discoloration consistent with heat damage.
The engine was retained for further examination.
Four people survived a plane crash east of the Fayetteville Regional Airport Friday night.
All four were taken to Cape Fear Valley Medical Center with what were believed to be non-life threatening injuries. The names of those on board, was not available.
Prior to the crash, the plane radioed to the airport its single engine had stopped working and it wasn't sure it could make the runway. Gene Booth, emergency management coordinator for the county, said the Federal Aviation Administration and National Transportation Safety Board were expected to investigate.
The four on board walked out with assistance from first responders, said David Hargis, a battalion chief with the Fayetteville Fire Department. He said it took first responders about 30 minutes to locate the Beechcraft A36, whose wings were knocked off as it crashed into a muddy, wooded area. The fuselage was left mainly intact.
Hargis said the plane had two hours of fuel left. The aircraft carries fuel in the wings, and some fuel was on the ground.
"A plane crash is never routine, at least for the Fire Department, but we practice and plan for it," Hargis said.
Airport fire officials contacted city fire officials in advance of the plane's crash when they learned of its engine trouble.
Hargis said machetes and axes were used to get to the plane, which was about 100 yards off the nearest solid surface.
The crash was in the Cumberland County Industrial Park, Booth said. The location was roughly the 2500 block of Clark West Road just off Cedar Creek Road, according to scanner traffic sending emergency responders to the scene.
Kevin Arata, a spokesman for the city of Fayetteville which runs the airport, said the plane never caught fire. He said response teams in the county went into a Level 3 response after learning of its emergency while still airborne.
Responders were able to quickly find the scene in part because of a call to 911, Arata said.
The plane crashed between 7:30 and 8 p.m. Conditions at the time were clear and unseasonably warm.
According to scanner traffic, voices could be heard immediately when responders reached the scene just before 8 p.m. Kevin Morgan, assistant fire chief for the Fayetteville Fire Department, confirmed all four survivors were taken to Cape Fear Valley and were out of the aircraft by the time it was located by emergency responders.
Booth said the area has been fortunate when it comes to airplane crashes.
"The last one I went to was over in Robeson County, just over the line," Booth said. "We've been very fortunate."
The last one at Fayetteville Regional is believed to have been in February 2012, when two people survived their single-engine Mooney M20TN airplane crashing along Runway 4/22 into a grassy area. The plane struck a utility pole and flipped, destroying the aircraft. Both occupants of the plane were treated for minor injuries at Cape Fear Valley.
Sources:
http://www.wral.com
http://abc11.com
All four people aboard the single-engine plane walked away with minor injuries. They were treated at Cape Fear Valley Medical Center.
Authorities responding to the plane crash - which included the Fayetteville Fire Department, Police Department, Cumberland County Emergency Management and Cumberland County Sheriff's Office - have yet to release the names of those onboard, or any information about where the plane's flight plans.
Gene Booth, emergency management coordinator for the county, said the Federal Aviation Administration and the National Transportation Safety Board were expected to investigate.
The pilot of the plane reported an engine problem and doubt of making it to the airport's runway. Airport fire officials contacted city fire officials in preparation, and a citizen's call to 911 helped them locate the plane at roughly the 2500 block of Clark West Road, which is off Cedar Creek Road near an edge of the Cumberland County Industrial Park.
The area is woody and was very wet Friday night, about 100 yards from a solid surface. The evening was clear and unseasonably warm when the crash happened between 7:30 and 8 p.m.
The plane's wings were knocked off in the crash, causing fuel to reach the ground. There was no fire and the fuselage remained mostly intact, responders to the site said.
CUMBERLAND COUNTY (WTVD) -- A small plane crashed in Cumberland County off Clark West Road.
Officials said it was two men and two women in their mid 40's.
Officials said the Beechcraft aircraft crashed in an industrial park about 6 miles from the Fayetteville Regional Airport after an in-flight emergency.
Our crew on the scene says the pilot told air traffic controllers he was having trouble and then the engine quit.
Emergency crews found the aircraft in a wooded area which is part of the industrial park. Authorities said all four people were outside of the aircraft when it was found.
The people on board have been taken to Cape Fear Valley Medical Center.
Officials did not release specifics on their conditions.
The NTSB has been notified and is sending a crew to the scene.
Officials say the Beechcraft A36 airplane that plummeted into a wooded, muddy area in Fayetteville on Friday night should be removed from the crash scene Tuesday.
"Usually, they're removed by a flatbed truck from a local recovery company," said Terry Williams, a spokesman with the National Transportation Safety Board. "We're not releasing who is moving it."
Williams said a preliminary report about the Beechcraft A36 crash should be released roughly seven to 10 business days after the incident.
The wreck analysis will include details about weather and conditions when the plane came to rest between trees near the 2500 block of Clark West Road between 7:30 and 8 p.m.
The Federal Aviation Administration is assisting with the investigation, Williams said.
"We'll also check the four corners of the plane: the nose, tail and two wings," he said. "Right now, we're not saying what has been found. We're still in the very, very early stages of this investigation."
It may take up to a year before the investigation is completed and authorities know why the plane crashed close to the Cumberland County Industrial Park, he said.
The planes' fuselage remained mostly intact, but both wings were knocked off in the crash. Fuel leaked into the ground.
The Beechcraft A36 has remained 2 1/2 miles east of the Fayetteville Regional Airport. The pilot reported an engine problem and expressed doubt at making it to the runway, cutting short the scheduled trip from Stevensville, Maryland, to Charleston, South Carolina.
Local and federal authorities have remained tight-lipped on releasing the names of the pilot and his three passengers. The two men and two women who occupied the plane walked away with minor injuries, said Fayetteville Fire Department Assistant Chief Kevin Morgan.
The pilot and passengers were taken to Cape Fear Valley Medical Center.
WTVD on Sunday reported the pilot's name as David McKee and a passenger as Erica Hoffman. Neither was listed as a patient at the hospital on Monday, a spokesman said.
Story and video: http://abc11.com
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