Feedback on S92a from a St. John's PAX
To all
I lost many work colleagues 7 days ago. I am an engineer with nearly 18 years offshore experience both in the North Sea and over 5 years in Canada, so let's just say I have hands-on experience of the S-92a issues. I was on one that developed a "hydraulic leak" back on 15 November 2006, thankfully we found it during a refuel on a drilling rig and the machine was shut down until Cougar came out and patched it up. My work colleagues and your fellow pilots were not so lucky.
I cannot believe that the FAA and CAA has not grounded all S-92a's until the root cause of our recent tragedy has been identified and rectified. I appreciate this network's information sharing and now have a more thorough understanding of the S-92a MGB issues. Surely the number of incidents in CADORS should have prompted a more robust fault investigation by Sikorsky prior to this failure.
We all have a responsibility to do our jobs as safely as possible. If this means that no S-92s are allowed to fly until the MGBs are made more robust and/or other modifications are done such as a fifth blade to reduce the inherent vibration that these units have, then so be it.
Here is a summary of the S-92 CADORS logs, and this is just for the St. John's based units. It is worth noting that post-July 2006 MGB housing and vespel spline FAA AD "recalls" the number of CHIP incidents seem to have dropped. As you can see there have been other "teething" problems with this helo over here. Note that the Nov 15 2006 incident was not recorded...
Date 1/18/2006
CADORS Number 2006A0038
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC
Description TSB Update A06A0005: CHI21, a Cougar Helicopter Sikorsky S-92A, with 18 passengers and two flight crew on board, was enroute from St. John's, NL to the Terra Nova FPSO oil production vessel when the number two engine chip light illuminated. The crew elected to return to St. John's and, on the return flight, they had indications of an oil filter bypass, excessive turbine gas temperature, and reduced oil pressure on the same engine. The crew shut down and secured the engine (General Electric CT7-8A), declared an emergency, and landed safely at St. John's without further incident. Maintenance inspection revealed significant metal particles on the engine chip plug and the oil filter and sump. The engine is being replaced and shipped to the manufacturer for further analysis
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 1/18/2006
CADORS Number 2006A0038
Event Diversion
Owner COUGAR HELICOPTERS INC
Description CHI21, Sikorsky S92A, enroute from St. John’s (CYYT) to Henry Goodridge Oil Rig, at 1459Z, declared an emergency due to an engine failure. Aircraft requested clearance back to CYYT. CHI21 landed safely at 1550Z. TSB Case Closed.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 2/3/2006
CADORS Number 2006A0073
Event Engine malfunction - other
Owner COUGAR HELICOPTERS INC
Description CHI22,S92, enroute St. John’s (CYYT) to – Henry Goodrich Oil Platform (CHEN) requested to return to CYYT due indication light at 1800Z, position 35NM southeast of CYYT(St. John's). Aircraft advised no emergency. At approximately time 1813Z flight requested ERS on arrival. Landed without further incident at time 1823Z. Pilot advised of engine chip light. TSB Case Closed
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 2/3/2006
CADORS Number 2006A0073
Event Engine malfunction - other
Owner COUGAR HELICOPTERS INC
Description UPDATE Maintenance & Manufacturing: This is the third CT7-8A engine in a S92 that has had this bearing fail, two of them in Cougar Helicopters aircraft. General Electric (GE) representatives have determined the first engine malfunction to be from external contamination of aluminum oxide left behind from the manufacturing process. They suspect and are quite confident the engines involved in the Cougar incidents were contaminated in the same way, but the lab reports are pending. General Electric has a full team investigating this problem. They have already modified their cleaning and flushing procedure. General Electric has implemented a 50 hour inspection of the mag plugs, which Cougar Helicopters have added to their inspection program, as well as adding a daily mag plug check for the next 100 hours and for 100 hours after any new engine install.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 2/3/2006
CADORS Number 2006A0073
Event Engine malfunction - other
Owner COUGAR HELICOPTERS INC
Description UPDATE : TSB A06A0010: CHI22, a Cougar Helicopters Sikorsky S-92A, with 19 passengers and two flight crew onboard, was enroute from St. John's, NL to the Henry Goodrich oil platform and was approximately 35 NM Southeast of St. John's when the number two engine chip light illuminated (General Electric CT7-8A). The crew followed checklist procedures and reduced the #2 engine power to idle and elected to return to St. John's. The crew did not initially declare an emergency, however, ten minutes prior to landing requested ERS. The aircraft landed without further incident. After the aircraft landed, maintenance inspected the chip plug on the #2 engine and in consultation with the engine manufacturer, it was felt that the metal found on the chip plug was from the #3 bearing. This engine had a total of 42.2 hrs time in service since new. The engine was replaced with a new engine before the aircraft was returned to service.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: The number 2 engine had not failed rather a chip light had illuminated resulting in the flight crew reducing power for that engine.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: A06A0071: Cougar 33 (C-GSCH), a Sikorsky S-92, was outbound from St. John's to Hibernia. At approximately 75 nm from St. Johns the INPUT CHIP 2 light came on. The crew followed the checklist, reduced No.2 engine to IDLE, descended to 500 feet, and joined Route B back to St. John's airport. Once level at 500 feet the crew briefed the passengers and ATC. Approximately 5 minutes after the INPUT CHIP 2 indication the INPUT CHIP 1 also illuminated. The crew declared a "PAN" and continued in to St. John's at 500 feet. A Cormorant on exercises in the area (OUTCAST 903) joined the aircraft and escorted the flight in to St. John's airport. The crew flew a running landing onto Runway 02, then shut down the aircraft on the runway to prevent damage to the gearbox inputs. Upon inspection, the chip plugs in the main transmission and in the associated accessory modules were found to be contaminated. The affected components will be changed out, and the company and manufacturer are investigating the cause of the chip lights.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: A06A0071: Cougar 33 (C-GSCH), a Sikorsky S-92, was outbound from St. John's to Hibernia. At approximately 75 nm from St. Johns the INPUT CHIP 2 light came on. The crew followed the checklist, reduced No.2 engine to IDLE, descended to 500 feet, and joined Route B back to St. John's airport. Once level at 500 feet the crew briefed the passengers and ATC. Approximately 5 minutes after the INPUT CHIP 2 indication the INPUT CHIP 1 also illuminated. The crew declared a "PAN" and continued in to St. John's at 500 feet. A Cormorant on exercises in the area (OUTCAST 903) joined the aircraft and escorted the flight in to St. John's airport. The crew flew a running landing onto Runway 02, then shut down the aircraft on the runway to prevent damage to the gearbox inputs. Upon inspection, the chip plugs in the main transmission and in the associated accessory modules were found to be contaminated. The affected components will be changed out, and the company and manufacturer are investigating the cause of the chip lights.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Engine malfunction - other
Owner COUGAR HELICOPTERS INC
Description At 20:20Z, CHI33, S92, enroute from St. John’s (CYYT) to the Hibernia Oil Platform, advised that the number 2 engine was out and that they were canceling IFR to return to St. John’s VFR. No emergency declared or assistance required. At 20:38Z, the pilot declared an emergency as the #1 engine indicated a malfunction as well. The aircraft landed safely at 21:02Z without further incident. TSB Case Closed.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Engine malfunction - other
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: The number 2 engine had not failed rather a chip light had illuminated resulting in the flight crew reducing power for that engine.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC
Description At 20:20Z, CHI33, S92, enroute from St. John’s (CYYT) to the Hibernia Oil Platform, advised that the number 2 engine was out and that they were canceling IFR to return to St. John’s VFR. No emergency declared or assistance required. At 20:38Z, the pilot declared an emergency as the #1 engine indicated a malfunction as well. The aircraft landed safely at 21:02Z without further incident. TSB Case Closed.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Diversion
Owner COUGAR HELICOPTERS INC
Description At 20:20Z, CHI33, S92, enroute from St. John’s (CYYT) to the Hibernia Oil Platform, advised that the number 2 engine was out and that they were canceling IFR to return to St. John’s VFR. No emergency declared or assistance required. At 20:38Z, the pilot declared an emergency as the #1 engine indicated a malfunction as well. The aircraft landed safely at 21:02Z without further incident. TSB Case Closed.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Diversion
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: A06A0071: Cougar 33 (C-GSCH), a Sikorsky S-92, was outbound from St. John's to Hibernia. At approximately 75 nm from St. Johns the INPUT CHIP 2 light came on. The crew followed the checklist, reduced No.2 engine to IDLE, descended to 500 feet, and joined Route B back to St. John's airport. Once level at 500 feet the crew briefed the passengers and ATC. Approximately 5 minutes after the INPUT CHIP 2 indication the INPUT CHIP 1 also illuminated. The crew declared a "PAN" and continued in to St. John's at 500 feet. A Cormorant on exercises in the area (OUTCAST 903) joined the aircraft and escorted the flight in to St. John's airport. The crew flew a running landing onto Runway 02, then shut down the aircraft on the runway to prevent damage to the gearbox inputs. Upon inspection, the chip plugs in the main transmission and in the associated accessory modules were found to be contaminated. The affected components will be changed out, and the company and manufacturer are investigating the cause of the chip lights.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 7/25/2006
CADORS Number 2006A0549
Event Diversion
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: The number 2 engine had not failed rather a chip light had illuminated resulting in the flight crew reducing power for that engine.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 8/8/2006
CADORS Number 2006A0599
Event Diversion
Owner COUGAR HELICOPTERS INC
Description CHI91, S92, enroute from St. John’s (CYYT) to the Sea Rose Drilling Platform, departed IFR at 17:05Z and at 17:08Z the crew cancelled IFR and returned to St. John's due to a mechanical issue. No emergency was declared and the aircraft landed at 17:13Z without further incident. Nil TSB.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 12/13/2006
CADORS Number 2006A1052
Event Engine oil problem
Owner COUGAR HELICOPTERS INC
Description CHI21, Sikorsky S92A, enroute from St. John’s (CYYT) to the Terra Nova Platform, aborted takeoff due to a low oil pressure indication. No assistance was required. Nil TSB.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 1/14/2007
CADORS Number 2007A0035
Event Diversion
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: A07A0004: CHI21, a Cougar Helicopters Sikorsky S-92, was en route from St. John's NL to the Henry Goodridge oil production platform when the flight crew noticed that the number one engine fuel pressure caution light had illuminated. The crew advised ATC that they were returning to St. John's and requested that the ARFF be on standby. The aircraft landed safely at St. John's without further incident. Maintenance inspection revealed that the cause of the incident was a defective fuel pressure switch. The switch has been replaced and the aircraft has since been returned to service.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 1/14/2007
CADORS Number 2007A0035
Event Engine oil problem
Owner COUGAR HELICOPTERS INC
Description UPDATE TSB: A07A0004: CHI21, a Cougar Helicopters Sikorsky S-92, was en route from St. John's NL to the Henry Goodridge oil production platform when the flight crew noticed that the number one engine fuel pressure caution light had illuminated. The crew advised ATC that they were returning to St. John's and requested that the ARFF be on standby. The aircraft landed safely at St. John's without further incident. Maintenance inspection revealed that the cause of the incident was a defective fuel pressure switch. The switch has been replaced and the aircraft has since been returned to service.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 3/22/2007
CADORS Number 2007A0211
Event Landing gear
Owner COUGAR HELICOPTERS INC
Description CHI31, Sikorsky S92A, enroute from St. John’s (CYYT) to the Hibernia Oil Platform, departed St. John’s at 12:04Z and was unable to retract the landing gear. The flight returned to St. John’s VFR and landed without incident at 12:51Z. Nil TSB.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 6/13/2007
CADORS Number 2007A0519
Event Diversion
Owner COUGAR HELICOPTERS INC.
Description A Canadian registered Sikorsky S92A, after departure from St. John’s (CYYT), requested to return to the airport due to an input chip light indication. The aircraft landed without further incident at 11:12Z. Nil TSB.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 2/11/2008
CADORS Number 2008A0187
Event Flight instrument failure
Owner COUGAR HELICOPTERS INC.
Description UPDATE TSB: The aircraft powered down and then back up. The malfunction did not reappear.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 2/11/2008
CADORS Number 2008A0187
Event Flight instrument failure
Owner COUGAR HELICOPTERS INC.
Description CHI51, Sikorsky S92A, enroute from St. John’s (CYYT) to the Glomar Oil Rig, departed St. John’s at 11:48Z. At 12:04, approximately 38 nautical miles southeast of St. John’s, the flight requested clearance to return to St. John’s. Pilot advised reason for return as "Computer Failure". No emergency declared and no assistance was required. The flight landed safely at 12:27Z. Nil TSB.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 4/24/2008
CADORS Number 2008A0501
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC.
Description CHI91, Sikorsky S92A, enroute from the Sea Rose Oil Platform to St. John’s (CYYT), declared an emergency due to an engine failure. The flight was 100 nautical miles southeast of St. John’s. The Rescue Coordination Centre (RCC) was advised. The flight landed safely at 15:03Z. TSB Case Closed.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 4/24/2008
CADORS Number 2008A0501
Event Engine failure
Owner COUGAR HELICOPTERS INC.
Description UPDATE TSB: A08A0059: The Cougar Helicopters Sikorsky-S92A , operating as CHI91, was in cruise flight en route from the Hibernia Gravity Based Platform to St. John's Intl. When the helicopter was approximately 100 NM SE of St. John's, NL the crew contacted Gander ACC to advise they were declaring an emergency and had shutdown engine #1 (GE CT7-8A). The engine shutdown was required due to a Gear Box chip light. The helicopter landed uneventfully at 12:35 NDT while ARFF were standing by. Maintenance determined the chip light was due to an accumulation of "nuisance fuzz" in the form of a "sliver" on a recently installed Main Gearbox accessory input.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 4/24/2008
CADORS Number 2008A0501
Event Engine failure
Owner COUGAR HELICOPTERS INC.
Description UPDATE Maintenance & Manufacturing: This incident is a follow on a ground chip light occurrence of April 16, 2008. The MGB Input Module was replaced on April 22, 2008 as a result of the April 16th chip light indication. This incident flight was the first offshore flight since the ground run and test flight after input module replacement. The MGB oil and filters have been replaced since this incident.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 6/30/2008
CADORS Number 2008A0787
Event Diversion
Owner COUGAR HELICOPTERS INC.
Description Shortly after departure from St. John’s (CYYT), CHI21, Sikorsky S92A, requested to return due to a minor mechanical problem with an anti-icing failure on Engine Number Two. No assistance was requested and the aircraft landed at 10:53Z.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 9/6/2008
CADORS Number 2008A1126
Event Door/canopy openings indications
Owner COUGAR HELICOPTERS INC.
Description CHI71, Sikorsky S92, aborted the departure due to a cargo door indication. No assistance was required.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 9/24/2008
CADORS Number 2008A1220
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC.
Description While inbound to St. John’s (CYYT) (70 nautical miles east of St. John's), a Canadian registered Sikorsky S92A, enroute from the Glomar Oil Rig, declared PAN PAN PAN due to a fire indication in the number-two engine. Crash Fire Rescue (CFR) was requested at destination and was standing by. The aircraft landed without further incident at 15:06Z.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 9/24/2008
CADORS Number 2008A1220
Event Declared emergency/priority
Owner COUGAR HELICOPTERS INC.
Description UPDATE Maintenance & Manufacturing: Cougar maintenance investigated the incident and found no engine contributing factors or obvious fire indication system problems. Due to the reliability history of the engine flame detectors, both detectors were replaced for precautionary reasons. There have been no reports of engine fire detection problems since the detector replacement and the situation is being monitored by management.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 9/24/2008
CADORS Number 2008A1220
Event False warning - engine fire
Owner COUGAR HELICOPTERS INC.
Description While inbound to St. John’s (CYYT) (70 nautical miles east of St. John's), a Canadian registered Sikorsky S92A, enroute from the Glomar Oil Rig, declared PAN PAN PAN due to a fire indication in the number-two engine. Crash Fire Rescue (CFR) was requested at destination and was standing by. The aircraft landed without further incident at 15:06Z.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 10/21/2008
CADORS Number 2008A1314
Event Rejected take-off
Owner COUGAR HELICOPTERS INC.
Description CHI21, Sikorsky S92, rejected take-off in St. John’s (CYYT) due to a cockpit indication and taxied back to the ramp. There was no operational impact.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 12/4/2008
CADORS Number 2008A1485
Event Diversion
Owner COUGAR HELICOPTERS INC.
Description UPDATE Maintenance & Manufacturing: Shortly after departure the crew had two indications of low fuel, the Segment Caution panel indicated Low Fuel and the Engine Instrument Caution Advisory System (ICAS) indicated Fuel 2 Low, a third indicator the Fuel Totalizer did not show a low fuel situation. The Fuel Totalizer showed 2,400 lbs. At this point the crew made the decision to return to St Johns. Upon landing a visual inspection revealed that the right hand fuel tank had enough fuel in to be visually inspected. The ensuing investigation revealed that the aircraft was left outside the night before, in heavy rain. The rain may have been a factor causing electrical anomalies however the investigation is ongoing and more details will follow.
Aircraft Model S92A
Aircraft Make SIKORSKY
Date 1/16/2009
CADORS Number 2009A0054
Event Rejected take-off
Owner COUGAR HELICOPTERS INC.
Description CHI91, Sikorsky S92A, enroute from St. John’s (CYYT) to the Searose Oil Platform, rejected takeoff from Runway 34 due to an instrument action problem. No assistance was required.
Aircraft Model S92A
Aircraft Make SIKORSKY