NTSB Identification: ERA16LA216
14 CFR Part 91: General Aviation
Accident occurred Friday, June 17, 2016 in Chatham, MA
Probable Cause Approval Date: 09/06/2017
Aircraft: ROBINSON HELICOPTER R44, registration: N141TM
Injuries: 2 Serious.
NTSB investigators may not have traveled in support of this investigation and used data provided by various sources to prepare this aircraft accident report.
The commercial pilot reported that, during an aerial photography flight, the helicopter was about 300 ft above a pond when it experienced an engine overspeed, followed by a loss of engine power. The pilot subsequently entered an autorotation to shallow water.
Examination of the engine revealed that the No. 2 cylinder head rocker shaft bosses, the No. 2 intake valve upper spring, and the No. 3 intake valve spring seat were fractured, consistent with an engine overspeed. Examination of the airframe revealed that the engine cooling fan shaft had separated. Without the resistance of the fan shaft, the engine oversped, which resulted in sufficient engine damage for the engine to lose total power. The aft face of the fan shaft’s lower sheave exhibited caked-on grease, consistent with grease leaking beyond the lower forward clutch actuator bearing seal for a prolonged period of time. Metallurgical examination of the bearing revealed that its rollers were seized, and no grease was recovered, consistent with a lack of lubrication.
The helicopter manufacturer’s maintenance manual required that the entire airframe be overhauled every 2,200 hours, which would include an overhaul of the engine cooling fan driveshaft lower bearing and seal. Review of maintenance records revealed that, due to a maintenance logbook entry error (time since overhaul) that occurred about 9 years before the accident and was carried forward, the helicopter had been operated about 52 hours beyond the mandatory airframe overhaul time limit. The manual also required that the lower clutch actuator bearings be lubricated every 300 hours or 3 years, whichever occurred first. Although the failed bearing had been lubricated with grease both about 1 year and 2 years preceding the accident, there was no record indicating that the bearing had been lubricated with grease during the preceding 4 years 11 months and 685.1 hours of operation, which likely damaged or degraded the bearing and led to its failure during the accident flight.
The National Transportation Safety Board determines the probable cause(s) of this accident as follows:
The inadequate maintenance of the lower forward clutch actuator bearing for a prolonged period of time, which resulted in a bearing failure. Contributing to the accident was an erroneous maintenance entry, which resulted in the helicopter being operated beyond its mandatory airframe overhaul time.
The National Transportation Safety Board did not travel to the scene of this accident.
Additional Participating Entities
Federal Aviation Administration / Flight Standards District Office; Boston, Massachusetts
Lycoming Engines; Williamsport, Pennsylvania
Robinson Helicopter Company; Torrance, California
Aviation Accident Factual Report - National Transportation Safety Board: https://app.ntsb.gov/pdf
Ryan Rotors Inc: http://registry.faa.gov/N141TM
NTSB Identification: ERA16LA216
14 CFR Part 91: General Aviation
Accident occurred Friday, June 17, 2016 in Chatham, MA
Aircraft: ROBINSON HELICOPTER R44, registration: N141TM
Injuries: 2 Serious.
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 June 17, 2016, about 1245 eastern daylight time, a Robinson R44, N141TM, operated by Ryan Rotors, was substantially damaged during a forced landing to a pond, following a total loss of engine power while maneuvering near Chatham, Massachusetts. The commercial pilot and passenger were seriously injured. The local aerial photography flight was conducted under the provisions of 14 Code of Federal Regulations Part 91. Visual meteorological conditions prevailed and no flight plan was filed for the flight that originated Plymouth Municipal Airport (PYM), Plymouth, Massachusetts, about 1026.
The pilot reported that the passenger hired him so that she could take aerial photographs of real estate. The helicopter was over a saltwater pond, about 300 feet above ground level, approaching homes near the shoreline. At that time, the pilot felt a lateral shudder followed by the clutch light illuminating. The helicopter then began a violent yaw and the low oil pressure light illuminated. The pilot subsequently performed an autorotation to shallow water near the shoreline.
Review of data downloaded and plotted from a handheld GPS revealed that the helicopter proceeded along the north shore of Cape Cod after departing PYM, then transitioned to the south shore near Dennis, Massachusetts. The helicopter continued along the south shore and in the Chatham, Massachusetts area, completing many circuits, consistent with aerial photography. The last two data points recorded indicated a GPS altitude of 402 feet and 268 feet, respectively.
Examination of the wreckage by a Federal Aviation Administration inspector revealed that the helicopter came to rest on its left side at the edge of a pond. The inspector observed substantial damage to the airframe and also noted that a rocker arm was protruding from the engine crankcase. The wreckage was examined again at a recovery facility. Examination of the engine revealed that the No. 2 and No. 3 cylinders exhibited damage consistent with engine overspeed. Specifically, the No. 2 cylinder head rocker shaft bosses were fractured and the No. 2 intake valve upper spring was fractured. The No. 3 intake valve spring seat was also fractured.
Examination of the airframe revealed that the engine cooling fan shaft had separated. Examination of the aft face of lower sheave revealed caked on grease, consistent with grease leaking beyond the lower forward clutch actuator bearing seal over a period of time. Metallurgical examination of the bearing revealed that its rollers were seized and no grease was recovered, consistent with a lack of lubrication (For more information, see Material Laboratory Factual Report in the NTSB Public Docket). The seal and bearing housing were severely damaged during the accident, which precluded determination of the exact point on the seal that was compromised.
Review of maintenance records that the helicopter's most recent 100-hour inspection was completed on April 23, 2016. At that time, the helicopter's total time airframe (TTAF) was noted as 2,192.4 hours and time since the airframe was overhauled (TSOH) was noted as 1,637.4 hours. Review of the helicopter's hour meter after the accident revealed that it had flown an additional 59.5 hours since that inspection, resulting in a TTAF of 2,251.9 and TSOH of 1,696.9 hours. Further review of the aircraft logbook revealed that a 100-hour inspection was completed on August 3, 2007, shortly after an engine overhaul. At that time, the TTAF was recorded as 559.2 hours and the TSOH was recorded as 4.2 hours; however, although the engine had been overhauled, the airframe had not been overhauled and the erroneous TSOH recording carried forward throughout the aircraft logbook. At the time of the accident, the TTAF and TSOH for the airframe were both 2,251.9 hours. The helicopter manufacturer required the airframe to be overhauled by the manufacturer every 2,200 hours, during which, the engine cooling fan driveshaft lower bearing and seal would have been overhauled.
Review of Robinson Helicopter Company Service Bulletin (SB)-42 revealed a requirement to service the lower clutch actuator bearings with grease every 300 hours or annually, whichever occurred first, to prevent failure due to lack of lubrication. The SB was superseded by an addition to the maintenance manual that required a similar procedure of every 300 hours or every 3 years, whichever occurred first. Review of the maintenance records revealed that the lower clutch actuator bearings were most recently serviced on December 17, 2015, at a TTAF of 2,095.1 hours. They were previously serviced on September 17, 2014 at a TTAF of 1,885.4 hours; however, prior to that, the last recorded servicing was on June 13, 2006 at a TTAF 559.2 hours, resulting in no recorded servicing during a period of 8 years and 1,326.2 hours of operation. Further, the maintenance manual also contained instructions to check the condition of the lower clutch actuator bearing seals at every 100-hour or annual inspection. The was no record of the failed seal having ever been replaced.
14 CFR Part 91: General Aviation
Accident occurred Friday, June 17, 2016 in Chatham, MA
Aircraft: ROBINSON HELICOPTER R44, registration: N141TM
Injuries: 2 Serious.
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 June 17, 2016, about 1245 eastern daylight time, a Robinson R44, N141TM, operated by Ryan Rotors, was substantially damaged during a forced landing to a pond, following a total loss of engine power while maneuvering near Chatham, Massachusetts. The commercial pilot and passenger were seriously injured. The local aerial photography flight was conducted under the provisions of 14 Code of Federal Regulations Part 91. Visual meteorological conditions prevailed and no flight plan was filed for the flight that originated at Plymouth Municipal Airport (PYM), Plymouth, Massachusetts, about 1200.
Two witnesses reported that the helicopter had been flying low for several minutes, just above trees over select properties. Both witnesses then heard a sputtering or lack of engine noise, followed by a landing that looked like "a controlled crash."
Examination of the wreckage by a Federal Aviation Administration inspector revealed that the helicopter came to rest on its left side at the edge of a pond. The inspector observed substantial damage to the airframe and also noted that a rocker arm was protruding from the engine crankcase.
The wreckage was retained for further examination.
CHATHAM — Eva Japowicz was doing her bills, writing checks in the kitchen at about 12:45 Friday afternoon, when she noticed a helicopter go past her windows, dropping below tree level.
“It didn’t sound as if anything was wrong,” she recalled.
Then came the thump heard by many in the neighborhood, as the helicopter hit the water close to the marshy edges of Crows Pond. Pilot John Ryan, 48, of Scituate, and his passenger, Tyra Pacheco, 48, of Acushnet both suffered serious injuries. Ryan was initially taken to Cape Cod Hospital, while Pacheco was picked up by a MedFlight helicopter at Barnstable Municipal Airport and flown to Massachusetts General Hospital in Boston with critical injuries.
Ryan was transferred to a Boston medical center, according to Cape Cod Hospital spokeswoman Robin Lord.
Eastward Ho! Country Club assistant golf pro Andrew Walkley was on the driving range and noticed the helicopter flying overhead about 10 minutes before it crashed.
“When it went down, it was a really loud thump,” Walkley said. “It was flying pretty low at that point and went over Crows Pond, where it was flying really low and it started coming down and the rotors started to sputter.”
Residents along this scenic part of the Chatham coastline said they are accustomed to seeing small helicopters like this one flying low.
Trees partially blocked his view, but Walkley could see the splash as the helicopter hit the water. Walkley ran down a nearby dock, dialing 911, he said.
“Other people saw it flying around the course and said it just didn’t look right, it didn’t sound right,” Walkley said. “It looked like he knew he was going down.”
The helicopter is owned by Ryan Rotors of Scituate, which flies three helicopters out of Plymouth Municipal Airport.
John Ryan has been flying helicopters since 1985 and has been a flight instructor for 22 years, with over 6,500 accident-free flight hours, according to the Ryan Rotors website. The website advertises services that include aerial tours, photography, golf ball drops and other fundraisers, powerline and pipeline patrols, spraying seeding and lift work.
He started flying helicopters when he was 19 and is married with 3 children, according to the website for Heliops LLC, a helicopter charter company where he worked as well.
Pacheco is an architectural and real estate photographer who shoots aerials, interiors and exteriors, according to her website. Her work has been featured in the Cape Cod Times.
“My journey toward becoming a photographer began with a degree in English, nearly a decade in hospitality management, and several years working as a freelance writer,” she wrote on her website.
The helicopter crashed is listed as a Robinson R44 Raven I, a four-seater. John Ryan and Ross Rossetti are pictured as pilots for Ryan Rotors. A woman who answered the phone listed for Ryan Rotors immediately hung up when a reporter identified himself.
Walkely said golfers and others attempted to cut through one of the pond-side properties and get down to the stricken helicopter.
“The girl was screaming, she was in a panic, and he (the pilot) was trying to help her,” Japowicz said.
Police and firefighters arrived quickly after the crash, witnesses said.
“We had multiple 911 calls,” said Chatham police Lt. Michael Anderson. “Both were conscious on arrival, both still harnessed in the machine.”
Witnesses told police the helicopter was flying at about 100 feet off the water at treetop level, and that there was no smoke, just a sputtering sound that drew their attention.
“Everyone said it was not a violent landing. It looks like the pilot did an excellent job of trying to save the aircraft and themselves because he didn’t put it into the trees,” Anderson said.
An hour after the crash, the helicopter rested partially on the marsh grass, its tail drooping into the water as the harbormaster’s boat deployed a boom intended to corral any spilled fuel. The machine looked flattened into the grass, as though someone had let the air out of an inflatable toy. The cockpit was folded over like a partially closed book.
Several news helicopters hovered overhead.
Rescuers had to cut through the aircraft's metal to free one of the two people inside, said Chatham Deputy Fire Chief Peter Connick.
“They both had multiple traumatic injuries,” Connick said. “They were both very seriously injured, but awake and active.”
Massachusetts State Police, a 42-foot rescue vessel from the Chatham Coast Guard station and a Jayhawk helicopter from Coast Guard Air Station Cape Cod all responded to the scene.
Anderson said the Massachusetts Aeronautics Division of the state Department of Transportation and a representative from the Federal Aviation Administration were expected on the scene Friday and would be conducting the investigation.
As of 5:45 p.m. Friday, Pacheco was not listed in the Massachusetts General Hospital system, according to a spokeswoman for the hospital.
Robinson R44 helicopters have had 364 incidents or crashes investigated by the National Transportation Safety Board since 1994.
Source: http://www.patriotledger.com
Chatham police said a small, two passenger helicopter went down into Crows Pond Friday afternoon.
Police tweeted that there were injuries in the crash.
Two ambulances brought patients to nearby Hyannis Airport where MedFlight helicopters were waiting.
One patient was transferred to the helicopter and transferred to an area hospital.
Another person was loaded onto a second MedFlight, but taken off a short time later and brought to the hospital by ambulance.
Both people appeared to be conscious.
Original article can be found here: http://boston.cbslocal.com
Flying over the crash scene, Sky5 could see the wreckage of the small helicopter at the edge of the water.
Photos from the ground show the bent rotor blades and broken fuselage.
"It wasn't an out-of-control 360-type of crash that was happening," said witness Neil Sullivan. "Just an increase in velocity as it was going. I saw it pass the tree line and heard the thud."
"We saw it was in the water so we ran up the street and down the driveway," said Sarah Holt. "There were a couple people already on the beach."
Reports indicate two people were hurt in the crash. They were put on backboards, carried up a wooden staircase and loaded into ambulances while Sky5 was overhead.
Sullivan said he heard the passenger from the helicopter screaming in pain.
"The pilot was fantastic, keeping the passenger calm, but he was definitely expressing the pain he was in," Sullivan said.
"I could hear the girl moaning and moaning. The man wasn't too much better. He was trying to calm her down," said Eva Japowicz.
The patients were then driven to an airfield where medical helicopters were waiting.
Story and video: http://www.wcvb.com
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