Serious incident to a crew member aboard Far Sword

Final report

Summary

In January 1995, the offshore supply vessel Far Sword, along with the offshore supply vessel Lady Audrey, was engaged in support of the United States drilling vessel Glomar Robert F Bauer, operating in the North Gorgon field on the Northwest Shelf, in 720 m water depth, 43 nautical miles (80 km) north-west of Barrow Island.

During the evening of 23 January, operations commenced on recovering the Glomar Robert F Bauer's anchors, preparatory to a move to a new drilling location, Altair No.1, in the Medusa field, 54 nautical miles (100 km) west of Barrow Island.

Glomar Robert F Bauer uses an anchor buoy system, the anchor recovery operation requiring each anchor buoy to be taken on board one of the supply vessels and the anchor hauled from the seabed using the buoy pennant wire.

On the morning of 24 January, while the three-man deck party of Far Sword was positioning an anchor buoy for securing on the aft deck, a sea broke over the stern and swept them up the deck. One of the seamen needed to be transferred to the Karratha hospital, where it was confirmed that he had a number of fractured ribs and a punctured right lung.

Conclusions

These conclusions identify the different factors contributing to the accident and should not be read as apportioning blame or liability to any particular person or organisation.

The injury to the rating was the result of a number of factors that, combined with the increasing sea conditions, made the anchor recovery a marginal operation:

  1. The inexperience of the ratings in anchor handling operations resulted in a lengthier operation and extended exposure time.
  2. The inexperienced ratings had to start the anchor handling operation during hours of darkness.
  3. The '24 hours a day' regime inhibited the Master from holding a lengthy operational and safety discussion with the crew before commencing anchor retrieval operations and from considering delaying operations until daylight.
  4. The lack of detailed planning resulted in the tugger wire not being deployed correctly.
  5. The solid design of the vessel's safety barrier provided very limited escape routes to the deck party, instilling an instinct to grab and hold on to the nearest object, rather than to move outboard of the barrier, or to climb up on it.
  6. The Bauer was not equipped with chain chasers, using instead an anchor buoy system, necessitating a long exposure time for the standby vessels' crews during anchor handling operations.

Occurrence summary

Investigation number 76
Occurrence date 24/01/1995
Location NW Australia
Report release date 19/09/1995
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Marine
Marine occurrence category Injury
Occurrence class Serious Incident
Highest injury level Serious

Ship details

Name Far sword
IMO number 8003979
Ship type Tug/supply vessel
Flag Norway
Destination Barrow Island, WA

Beech Aircraft Corp B200C, VH-AMB

Safety Action

As a result of this and other occurrences, together with a systemic investigation of the Class G Airspace demonstration, the Bureau of Air Safety Investigation issued interim recommendation IR980253 to the Civil Aviation Safety Authority on 8 December 1998:

"The Bureau of Air Safety Investigation believes that the Class G Airspace Demonstration has served its purpose. In the light of the safety concerns identified by this investigation, BASI recommends that the Civil Aviation Safety Authority should now terminate the demonstration. The results of the demonstration should be subject to a comprehensive evaluation that specifically addresses the safety concerns identified by BASI.

The evaluation process should take into account the time required to:

  1. review and analyse the demonstration;
  2. refine the model where required and conduct a proper safety analysis; and
  3. provide a comprehensive and effective education and training program for any subsequent changes to Class G Airspace.

If this is not achieved, the deficiencies identified in this investigation are likely to be repeated, thereby seriously compromising the successful introduction of future changes to airspace including reintroduction of Class G Airspace incorporating Radar Information Service and National Advisory Frequency".

The Bureau of Air Safety Investigation simultaneously issued the following related interim recommendations to the Civil Aviation Safety Authority:

"IR980260

The Bureau of Air Safety Investigation recommends that the Civil Aviation Safety Authority review program management policies and procedures for current and proposed changes to the aviation system, in the light of experience gained from the present Class G Airspace Demonstration.

IR980261

The Bureau of Air Safety Investigation recommends that the Civil Aviation Safety Authority, the Department of Transport and Regional Services and Airservices Australia review and clarify the roles and responsibilities of the respective organisations in relation to the regulation, design and management of airspace to ensure the safety integrity of the aviation system".

The Bureau of Air Safety Investigation simultaneously issued IR980261 to the Department of Transport and Regional Services and Airservices Australia as IR980256 and IR980257 respectively.

Subsequently, the Minister for Transport and Regional Services announced in Parliament on 9 December 1998 that the demonstration would cease on 13 December 1998.

Significant Factors

  1. The Beech pilot and the Saab crew did not hear the taxi or departure transmissions from each other on the MBZ frequency.
  2. The air traffic control radar was unable to detect aircraft at an altitude that would have enabled the controller to provide pilots with timely traffic information.

Analysis

The pilots of both aircraft were reliant on mandatory radio broadcasts to gain an awareness of other traffic operating within the confines of the MBZ. It is possible that they had simultaneously broadcast their respective taxi reports, thus blocking each other's transmissions. However, it is more likely that radio transmissions were inhibited by terrain shielding, resulting in neither crew being aware of the other aircraft while they taxied and departed. The demonstration procedures created a situation where pilots had one opportunity to become aware of other traffic. If they missed an MBZ broadcast, there was no other formal procedure to provide that information.

If a directed traffic information service had been in place at the time of this occurrence, a potential confliction would have been recognised by a third party. Traffic information would have been provided to the Beech pilot and the Saab crew, even if the MBZ reporting procedures had failed. In the past, the directed traffic information service provided a level of redundancy to the aviation system that was not available during the Class G airspace demonstration.

The radar information service was limited by the inability of the radar to detect aircraft at relatively low altitudes in that area. Despite attempts to obtain a radar advisory service as soon as possible after departing Lismore, the Beech pilot was unable to obtain traffic information from the radar controller. Supplementation of the radar information service with a directed traffic information service in such an area of limited radar coverage, would have enhanced the situational awareness of the respective flight crews. Alternatively, the provision of radar coverage from ground level to the lower limit of controlled airspace, together with a radar information service for taxiing aircraft, would have also minimised the potential for confliction.

A conflict was ultimately avoided because the pilots were using the air traffic control frequency. This was despite the fact that both aircraft were still operating within the MBZ and monitoring the MBZ frequency.

Summary

A Beech 200 was conducting an instrument flight rules (IFR) flight from Lismore to Glen Innes. The pilot gave a departure report to the Brisbane Sector 2 radar controller, and reported climbing through 3,500 ft. The controller advised that there were no other aircraft observed on the radar display. That departure report was also heard by the crew of an IFR Saab SF-340 that had just departed Casino on a flight to Williamtown, via Point Lookout. The Saab was climbing through 2,700 ft when the crew became aware that both aircraft were approximately 5 NM south-west of Lismore. The Saab crew descended to 2,500 ft, in order to establish 1,000 ft vertical separation from the Beech. The Saab crew subsequently saw the Beech pass from left to right, about 1 NM in front of their aircraft, as the Beech climbed through patches of cloud just under the main cloud base of 4,000 ft. The Beech pilot also saw the Saab pass below his aircraft.

Due to their proximity to each other, Lismore, Ballina and Casino aerodromes were encompassed by a non-standard Mandatory Broadcast Zone (MBZ), and used a common radio frequency of 124.2 MHz. The MBZ was approximately 60 NM long and 30 NM wide, and extended from the ground to 5,000 ft above ground level. The intent of the common frequency was to enable pilots operating at any of those aerodromes to hear transmissions from other pilots, so that they could coordinate operations in order to minimise the risk of conflict. Pilots were required to monitor the MBZ frequency when operating within the MBZ. They were also required to broadcast flight details when inbound to, taxiing at, and departing from an aerodrome within the MBZ.

The pilots of both aircraft had made the required broadcasts; however, neither received a response from any other aircraft. While taxiing at Lismore, the Beech pilot had monitored a transmission on the MBZ frequency from another pilot, but disregarded it as that aircraft was operating in the Ballina area. A recording device was installed at Lismore aerodrome to monitor aircraft using that facility. The majority of recorded transmissions from aircraft operating at Lismore were clear. Transmissions recorded from aircraft operating at Ballina and Casino were generally clipped or garbled, and more difficult to understand. The Saab crew later reported that pilots of aircraft on the ground at Lismore were unlikely to hear radio transmissions from aircraft on the ground at Casino, and vice versa.

At the time of the occurrence, both aircraft were operating in non-controlled Class G demonstration airspace. As part of that demonstration, modified procedures had been introduced, including the removal of the directed traffic information service previously provided by flight service, and the introduction of a radar information service provided by air traffic control. The provision of that service to pilots was dependent upon their aircraft being radar-identified. The secondary surveillance radar code from the Beech was not detected by the air traffic control radar system until it had climbed through an altitude of 3,300 ft. The Saab was not detected until it had climbed through approximately 3,000 ft.

Prior to the commencement of the demonstration, pilots of IFR aircraft were provided with traffic information on other IFR aircraft, in accordance with guidelines detailed in the Manual of Air Traffic Services and the Aeronautical Information Publication. Pilots operating an IFR flight from a non-controlled aerodrome were required to contact flight service by radio when taxiing. A flight service officer would then provide traffic information to pilots of conflicting aircraft that were not on the MBZ frequency. Based on that procedure, the Saab crew and Beech pilot would not have been provided with mutual traffic information, as they were both operating on the MBZ frequency at about the same time. However, traffic information was required to be passed to pilots of IFR aircraft climbing or descending through the level of another conflicting IFR aircraft. The overriding intent of the traffic information service was to issue such information if there was any doubt regarding the possibility of a confliction.

The Beech pilot had requested radar service information from air traffic control while taxiing at Lismore. The controller issued the pilot with a secondary surveillance code for the flight and advised that a radar information service would be provided when the aircraft was identified on radar, and that there were no other aircraft observed in the area.

Both aircraft were fitted with dual very high frequency (VHF) radio transmitters and receivers. The pilots were monitoring the MBZ frequency on one receiver while also monitoring the air traffic control frequency on the second receiver, in preparation for requesting a clearance to enter Class E controlled airspace at 8,500 ft. The Beech pilot stated that he normally would not have monitored the air traffic control frequency until passing 4,000 ft, but decided to contact the controller early to request the radar information service. Prior to the commencement of the demonstration period, pilots would normally have simultaneously monitored the MBZ and flight service area frequencies to assist in maintaining their situational awareness during the departure phase.

Occurrence summary

Investigation number 199804984
Occurrence date 10/11/1998
Location 9 km SW Lismore, (NDB)
State New South Wales
Report release date 22/07/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Separation issue
Occurrence class Incident
Highest injury level None

Aircraft details

Manufacturer Beech Aircraft Corp
Model 200
Registration VH-AMB
Serial number BL-131
Sector Turboprop
Operation type Aerial Work
Departure point Lismmore, NSW
Destination Glen Innes, NSW
Damage Nil

Aircraft details

Manufacturer Saab Aircraft Co.
Model 340
Registration VH-SBA
Sector Turboprop
Operation type Air Transport Low Capacity
Departure point Casino, NSW
Destination Williamtown, NSW
Damage Nil

Aero Commander 500-S, VH-UJP, Horn Island Aerodrome, Queensland

Summary

FACTUAL INFORMATION

History of the flight

At approximately 0910 EST, the aircraft took off from runway 32 at Horn Island and commenced a normal climb. Shortly after, it adopted a nose-high attitude and commenced a wingover type manoeuvre to the right. Witnesses described the aircraft as being in a nose-low attitude, and at a height of approximately 600 ft to 700 ft above ground level after the completion of this manoeuvre. It then abruptly adopted a level attitude and rapidly entered a spin to the left.

Witnesses on the ground reported that at approximately the same time as the aircraft entered the spin, engine power became asymmetric, with the right engine continuing to deliver considerable power. The aircraft continued to descend in a fully developed flat spin, with no observed signs of an attempt to recover. The impact was heard shortly after the aircraft descended behind vegetation to the north-west of the aerodrome. The accident was reported to Flight Service by radio at 0918.

The wreckage was located on a beach approximately 2 km to the north-west of the aerodrome. The aircraft was destroyed by impact forces and the pilot sustained fatal injuries.

Wreckage examination

Examination of the wreckage indicated that the aircraft had impacted the ground in an almost flat attitude while rotating in an anticlockwise direction.

Examination of the airframe and flight control systems did not reveal any pre-impact malfunction or defect which may have contributed to the accident.

Damage to the right engine, and propeller blade slash marks on the trunks of trees at the accident site, indicated that the right engine was producing considerable power at impact. The left propeller was in the feathered position. The left engine and propeller were removed from the wreckage for further examination. There was no evidence of pre-existing defects. Subsequent tests determined that the engine was capable of producing power prior to impact.

Maintenance history

A review of the aircraft, engine and propeller logbooks found nothing to suggest any irregularity that was likely to have affected the normal operation of the aircraft during this flight.

Pilot information

The pilot was the holder of an Australian commercial pilot licence for aeroplanes.  He held a valid medical certificate, multi-engine command instrument rating and grade one instructor rating. At the time of the accident, he was the chief flying instructor for the company's flying school and carried out check-and-training duties for the company's charter operations. He had accumulated approximately 11,740 flying hours, of which 7,750 hours were acting as pilot in command of multi-engine aircraft.

The pilot was endorsed on the Aero Commander 500S on 15 October 1993 and had accumulated in excess of 119 hours on type. He had flown the accident aircraft on a number of occasions.

Results of the post-mortem and toxicological examination of the pilot did not indicate signs of incapacitation due to a medical condition or the presence of drugs or alcohol.

A review of the pilot's activities in the 72 hours prior to the accident established that he had been flying for another company in Cairns during the previous weekend. He had a late night on Sunday and was observed to consume a considerable amount of alcohol and smoke heavily on this occasion, activities which he reportedly had not engaged in for some time. He was described as in good spirits on Monday morning and departed for Horn Island during the afternoon. Monday evening was spent with other company employees at the local motel. During this period, he was not observed to consume alcohol. He returned to the company's accommodation on the island with one of the company pilots. They spent a short time talking before retiring at approximately 2200.

On the morning of the accident, the pilot was rostered to train one of the company pilots on the Aero Commander 500. After arriving at the airport by bus at approximately 0900 EST, he was observed to walk through the terminal and proceed directly to the aircraft. He was not wearing his uniform. Shortly after, the pilot was observed to start the engines of the aircraft and taxi to the runway holding point. Witnesses reported that they did not observe the pilot carry out a pre-flight inspection of the aircraft or any pre-take off engine checks.

Weather

At the time of the accident the wind was a light south-easterly and there was scattered cloud with a base of approximately 1,800 ft. The weather was not considered a factor in this occurrence.

ANALYSIS

The investigation established that the aircraft was capable of normal operation prior to impact. No evidence was found to indicate that the performance of the pilot was affected by any physiological condition which may have adversely influenced his ability to carry out his tasks.

As a result of discussions with a number of witnesses and friends of the pilot, it is apparent that his behaviour immediately prior to the accident was not in keeping with what most described as his thorough and professional attitude to aviation. Witnesses and friends also stated that they had never known the pilot to commence a flight when not wearing his uniform and without having carried out a pre-flight inspection of the aircraft or any pre-take-off engine checks.

The aircraft entered a flat spin at a height from which recovery may have been possible. The reason the aircraft entered the spin and subsequently crashed could not be determined.

CONCLUSIONS

Findings

  1. The pilot held a valid pilot licence and medical certificate.
  2. The pilot was endorsed on the aircraft type.
  3. The aircraft entered a flat spin to the left with no reported signs of an attempt to recover.
  4. The aircraft struck the ground whilst established in a flat left spin.
  5. The right engine was producing considerable power prior to impact.
  6. Indications were that the left engine was producing little or no power. Its propeller was in the feathered position prior to impact.
  7. No evidence was found to indicate a malfunction or pre-existing defect with the aircraft or its systems which may have affected normal operation during this flight.
  8. No evidence was found to indicate pilot incapacitation as the result of a medical condition or the presence of alcohol or drugs.
  9. The pilot's behaviour on the morning of the accident was not consistent with what was generally accepted to be a thorough and professional attitude to aviation.

Occurrence summary

Investigation number 199504247
Occurrence date 12/12/1995
Location Horn Island Aerodrome
State Queensland
Report release date 15/10/1996
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Collision with terrain
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Aero Commander
Model 500
Registration VH-UJP
Serial number 3074
Sector Piston
Operation type Private
Departure point Horn Island, QLD
Destination Horn Island, QLD
Damage Destroyed

Cessna 182Q, VH-DFR, 16 km west of Bundaberg Aerodrome, Queensland

Summary

FACTUAL INFORMATION

Sequence of Events

The flight was planned to transport three passengers to Agnes Waters, returning on the same day.

The pilot commenced planning about two weeks before the flight. On the morning of the flight, he submitted a visual flight rules (VFR) flight plan which was received in Brisbane at 0543 EST. The flight plan indicated a planned departure time from Maroochydore of 0630, to cruise at 6,500 ft tracking about 5 NM west of Bundaberg and with a search and rescue time (SARTIME) for Agnes Waters of 1100.

At 0708 the pilot reported to Brisbane Flight Service that he was descending to 3,500 ft due to cloud. This was the last known radio transmission from the pilot.

Witnesses heard the aircraft circling for 5-10 minutes in the Kolan South area (10 NM west of Bundaberg airport) at about 0740. The engine sounded normal, the sound fading and increasing as the aircraft circled. One witness reported hearing a burst of engine power immediately followed by the sound of ground impact. None of the witnesses saw the aircraft before the accident.

The wreckage was found in an open, fallow cane field. The accident was not survivable, and all four occupants were killed by impact forces.

Pilot in Command

The pilot held a valid class 2 medical certificate for a private pilot licence. There was no known medical condition which could have contributed to the accident.

The pilot was adequately rested prior to the accident.

Of his 342 flying hours, the pilot had completed 32 hours on this type of aircraft. He had flown 4 hours (2 hours on type) in the previous 90 days.

Three days before the accident, the pilot had taken part in a club competition with an instructor pilot seated in the right seat. The competition included a climb under simulated instrument meteorological conditions (IMC) from 500 ft to 2,000 ft and some 45-degree angle of bank turns. This exercise was completed to the satisfaction of the instructor pilot. The pilot had logged 7 hours instrument flight time although he did not hold an instrument rating.

The pilot's last biennial flight review was conducted five months before the accident.

Meteorology

Over the period of the flight, the general weather in the area consisted of a very moist, unstable light northerly flow ahead of a trough to the west of the Great Dividing Range. Winds below 5,000 ft were north-westerly at less than 15 kts. In the Maroochydore area at 0600 there was scattered cumuliform cloud with a base around 3,000 ft and broken middle level cloud. ('Scattered' indicates 1-4 octas of cloud cover and 'broken' 5-7 octas.) Further north, the main base lowered and became broken to overcast by Maryborough.

The area forecast (ARFOR) for Area 40 covering the period 0130 to 1800 issued by the Bureau of Meteorology indicated thunderstorms and showers clearing from the coast by 0400 and redeveloping after 1200. The amended Area 40 forecast for the period 0600 to 2100 indicated scattered showers on the coast north of Bundaberg until 0900, isolated showers until 1200 and scattered showers and thunderstorms after 1200.

Terminal area forecasts (TAFs) and amended TAFs issued for Maryborough and Bundaberg were similar. The forecast issued at 0426 indicated a light northerly wind, scattered cumulus cloud and temporary periods after 1300 (up to 60 minutes) of thunderstorm activity. These forecasts were amended at 0725 to reflect intermittent periods (up to 30 minutes) of reduced visibility, showers, rain, and low cloud for the period from 0700 to 1300; and again at 0803 to predict intermittent periods of thunderstorms and rain between 0800 and 1300.

A pilot who arrived at Bundaberg at about 0710 from Archerfield stated that conditions were visual until about 20 NM south of Bundaberg when he encountered heavy rain. Maryborough had some cloud, but the circuit area was visual. He made a distance measuring equipment (DME) arrival to Bundaberg down to 840 ft before landing. He stated that there were lower patches of cloud with rain, and he estimated the cloud base on departure 25 minutes later to be about 900 ft.

A second pilot departed Bundaberg soon after 0700. He said the cloud base was about 400 ft, broken and in layers. There was no rain, and visibility was about 10 NM.

A third pilot who also departed soon after 0700 reported scattered cloud at about 300 ft in layers and that the coastal route to the south-east appeared to be good. To the north-west through north to the north-east, visibility was restricted in falling rain. He said the cloud extended to Flight Level (FL) 170.

A pilot who arrived at 0905 said that the cloud was unbroken from FL160 to 600 ft from 30 NM south of Bundaberg. There were build-ups with heavy rain to the north and south of Bundaberg.

Witnesses on the ground in the South Kolan area reported hearing a thunderstorm at the time of the accident. They reported low cloud and light rain.

Communications

A transmission from the pilot at 0708 was the last recorded transmission from the aircraft. The Bundaberg aviation data tape did not record any transmissions from the accident aircraft.

An analysis of the appropriate radar tapes did not indicate any trace of the aircraft.

Wreckage and Impact

The aircraft had impacted the ground in a steep nose-down attitude, right wing low, while rotating to the right. The aircraft disintegrated on impact, with the majority of the wreckage coming to rest about 23 m forward of the initial impact site.

The right wingtip had struck the ground first about 4 m before the main impact, followed by the right mainwheel.

After the main impact, the aircraft broke up, with sections of wreckage found up to 60 m from the main impact point. Fuel was spread over a wide area to the right of the wreckage centreline; consequently, the wreckage did not burn.

Both wings displayed typical evidence of in-flight overstress in a positive 'g' direction, indicating a possible attempt to recover the aircraft to level flight before impact. All control surfaces were present and control cables and push rods were still attached although severely disrupted.

The engine was subjected to an on-site examination and later to a partial tear down. No pre-accident fault could be found with the engine. The lack of pre-impact damage is supported by witness evidence of hearing the sound of an aircraft's engine.

Other components were examined in an attempt to determine aircraft configuration, attitude, and serviceability. The attitude indicator gyro and the vacuum pump both showed signs of operation before impact, but the degree of damage made obtaining any useful information from any of the other recovered components impossible. A further difficulty was encountered in finding small components due to their wide distribution and a combination of soft soil and torrential rain.

The aircraft was fitted with a Trimble global positioning system (GPS) mounted on the instrument panel with tape but not connected to the aircraft. The pilot had prepared the GPS the day before the accident and had asked for help from another pilot to program it. One pilot claimed that it was not an easy GPS to use and that he had difficulty turning it on. No information was recovered from the GPS.

Emergency Locator Transmitter

The aircraft was equipped with a fixed Dorne and Margolin 6.1 emergency locator transmitter (ELT) which complied with TSO C91. The ELT was severely damaged in the accident and failed to operate.

Weight and Balance

The aircraft's weight was estimated at 1,270 kg at take-off, which is within weight limits. Load distribution could not be determined.

Aircraft Documentation

The current maintenance release was not found at the accident site. However, previous maintenance releases and aircraft logbooks indicated that all relevant engine and airframe airworthiness directives were incorporated and that the aircraft should have been serviceable for the flight.

ANALYSIS

The pilot probably held ARFORs and TAFs issued at 0130 and 0426 which indicated little concern for the period of the flight to Agnes Waters and return. The ARFOR indicated only scattered showers for the period and the TAF predicted scattered cumulus cloud. Consequently, the pilot probably had few concerns about proceeding VFR on his planned track.

A TAF issued for Bundaberg at 0725 indicated intermittent periods from 0700 to 1300 of reduced visibility, showers, rain, and cloud at 900 ft. The pilot was probably not aware of this forecast.

The aircraft seemed to be serviceable at the time of impact. The engine was operating, and the airframe was intact. No evidence was found to suggest any flight control circuit failures. Damage to the attitude indicator gyro and the vacuum pump indicated that both of these components were operating at impact. Consequently, the aircraft flight instruments were probably operating normally.

The pilot was considered to be cautious and conscientious in his approach to flight preparation and in-flight procedures. He commenced planning the trip two weeks before departure by discussing the route with instructor pilots and preparing a chart. He had sought help in preparing the GPS and participated in a club competition three days before the accident. On the day of the flight, the pilot had submitted a flight plan.

About 30 minutes before the accident the pilot had descended to avoid cloud. This indicates that his intention was to continue with the planned flight and to remain visual. However, at some point near Bundaberg the aircraft entered cloud. This may have been inadvertent, or the pilot, relying on the forecast which he held, may have decided to fly through what he thought was a small area of cloud.

Witnesses reported the aircraft circling for up to 10 minutes and during this manoeuvring, the pilot probably entered a thunderstorm. A combination of low instrument hours, no instrument rating and turbulence in the cloud could lead to pilot disorientation and loss of control.

CONCLUSIONS

Findings

  1. The pilot in command held a valid pilot licence.
  2. The pilot in command did not hold an instrument rating.
  3. There was no evidence found to indicate that the performance of the pilot in command was adversely affected by any physical or medical condition.
  4. There was no evidence found to indicate that the aircraft was other than airworthy for the flight.
  5. The weather forecasts obtained by the pilot indicated that the weather was suitable for the flight as planned.
  6. The pilot submitted a VFR flight plan for the Maroochydore to Agnes Waters route.
  7. While en route, the weather deteriorated, necessitating a descent by the aircraft.
  8. Amended forecasts issued while the aircraft was in flight were probably not received by the pilot.
  9. The aircraft entered cloud.
  10. The accident was not survivable.

Significant Factors

  1. Weather conditions encountered south of Bundaberg were considerably worse than the forecast held by the pilot.
  2. The pilot allowed the aircraft to enter cloud.
  3. The pilot in command lost control of the aircraft and was not able to recover control before ground impact.

Occurrence summary

Investigation number 199504139
Occurrence date 06/12/1995
Location 16 km west of Bundaberg Aerodrome
State Queensland
Report release date 24/10/1996
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category VFR into IMC
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Cessna Aircraft Company
Model 182
Registration VH-DFR
Serial number 18266553
Sector Piston
Operation type Private
Departure point Maroochydore, QLD
Destination Agnes Waters, QLD
Damage Destroyed

Bell 205, 30257

Safety Action

At the request of and under the direction of BASI, the engine manufacturer investigated several engine failure modes during the investigation, including the misalignment of the reduction gearbox carrier housing assembly bearing bores

Following the accident the engine manufacturer has introduced an improved design N2 spur gear nut retainer and updated the overhaul assembly instructions for this component. The new nut retainer was incorporated to prevent tang fatigue failures. The improvement to the nut retainer was instituted as a result of an investigation into nut retainer failures in the U.S. Army UH-1 helicopter fleet. This investigation was initiated in April 1994.

An improved nut retainer was introduced on 13 Mar 1996 (Illustrated Parts Catalogue Temporary Revision No 6). Updated assembly instructions involving the match marking of the retainer and gearshaft, lubrication of the nut and a doubling of the torque on the nut were also introduced on 13 Mar 1996 (Overhaul Manual Temporary Revision No 16). A Service Bulletin (T5313B/T5317-0081) requiring replacement of nut retainers with improved retainers within 300 hours or two years was issued in May 1996. The Service Bulletin cites several instances of spur gear nut retainer separation in the U.S. Army T53 fleet. An Airworthiness Directive (AD 97-07-05) mandating the requirements of the Service Bulletin was issued by the U.S. Federal Aviation Administration in June 1997.

Factual Information

Survival

The pilot survived the crash but suffered multiple injuries. He undid his safety belt on the right front seat and exited the helicopter from the damaged left side. However, he died before the wreckage was located. The accident was potentially survivable. The pilot carried his flying helmet in the helicopter but had elected not to wear it for the ferry flight. He suffered serious head injuries.

Pilot information

The pilot held a Canadian commercial helicopter pilot licence. He was endorsed on the Bell 205. His total flight time was 10,092 hours, of which 9,992 had been flown in helicopters. He had flown approximately 3,600 hours in the Bell 205. His last company flight cheek was on 13 June 1995. He passed his last aviation medical examination on 7 November 1995. He was experienced in carrying out helicopter fire-fighting operations.

Medical information

The pilot's medical certificate required the use of vision correction lenses when flying. Evidence at the accident site indicated that he was probably wearing spectacles at the time of the accident. The only physiological condition subsequently found, which may have slightly affected his flying performance, was due to skin irritation, after being doused with jet fuel while refuelling just before departing Cockatoo.

Damage to aircraft

The helicopter was destroyed during the impact sequence. There was no post-impact fire.

Weight and balance

The helicopter was within its approved weight-and-balance limits at the time of the accident.

Weather

The wind was reported to be north-westerly at about 5 kts. The cloud was one or two oktas of stratocumulus at 5,000 ft. Visibility was in excess of 10 km. The weather was not a factor in the accident.

Aids to navigation

The helicopter was equipped with a global positioning system (GPS) which would have allowed the pilot to accurately fly a direct track to Benalla.

Wreckage information

No fault was found with the airframe or electrical systems of the helicopter. On-site examination of the wreckage indicated a loss of drive from the engine to the main transmission. The core engine was found to be physically disconnected internally from the main engine output gearbox. The engine chip detector was found to be heavily contaminated with metallic debris. A subsequent engine teardown inspection identified that the engine output gearbox had suffered significant damage and was the source of the drive failure. A discontinuity found in the engine chip detector wiring was assessed as impact damage.

Maintenance summary

Maintenance history was obtained from journey logs, engine logs and Transport Canada Aircraft Technical logs (engine and airframe). The following is a summary of maintenance data relevant to the engine fitted to GFHO at the time of the accident:

  • 04 Apr 1992; engine, serial number LE-07683C, upgraded from T53-13B to T53-17A configuration at 6,624 hours time since new (TSN).
  • 16 May 1994; engine LE-07683C overhaul completed at 7,020.4 hours TSN.
  • 17 Aug 1994; engine LE-07683C fitted to GFHO.
  • 05 Sep 1995; governor input seal leaking. Governor assembly replaced with overhauled unit.
  • 08 Sep 1995; GFHO last flight in Canada.
  • 25 Sep 1995; 100 hr inspection complied with in accordance with Bell 205 M & 0 and Lycoming manuals. Engine chip plug contains small amount of fuzz. All remaining screens and detectors found free and clean of debris.
  • 29 Sep 1995; engine LE-07683C accessory gearbox, serial no. 4029 replaced when copper-coloured metal contamination was found in the airframe paper filter. Accessory gearbox, serial no. 5154-6 (17.5 hours time since overhaul) fitted in accordance with Lycoming MM. Ground run & leak check complied with.
  • 04 Oct 1995; helicopter GFHO disassembled and shipped to Australia.
  • 24 Nov 1995 (late entry 19 Dec 95); engine LE-07683C, N2 torquemeter boost pump, serial no. Cl 198 replaced when "oil not scavenging from N2 gearbox and brass found in engine filters". N2 torquemeter boost pump, serial no. LA7278 fitted. "Pump removed has internal damage to brass bushings and the shaft has moved forward and uncoupled from pump".
  • 28 Nov 1995; helicopter GFHO reassembly completed in Australia.
  • 29 Nov 1995; GFHO first flight in Australia.
  • 13 Dec 1995; at the time of the accident, engine time logged in Australia approximately 4.5 hours, engine had accumulated approximately 7,413.0 hours TSN and therefore 392 hours time since overhaul (TSO).

Post accident maintenance observations

  • Oct 1995; according to the operator, the accessory gearbox removed on 29 Sep 1995 was disassembled and found to be acceptable for continued use and not responsible for the oil contamination found in the filter. It was decided that the N2 torquemeter boost pump may have caused the metal contamination and that this should be replaced when the aircraft was re-assembled in Australia.
  • 24 Nov 1995; the torquemeter boost pump, as well as suspected to be the source of metal contamination, was considered to be responsible for a previous oil leak. According to the operator, the oil leak mentioned was discovered during the governor change on 5 Sep 1995. Subsequent inspection of the replaced pump found incorrect assembly had led to gouging of a brass bushing and generation of brass contamination.

Engine teardown inspection

An engine teardown inspection revealed that the helical sun gearshaft was uncoupled from the output reduction gearbox. The helical sun gear is coupled to the power shaft and drives the reduction gearing. Output power is extracted from the reduction gearing through an externally splined output shaft. The uncoupling resulted in the loss of drive from the engine to the main transmission. Disassembly also revealed:

  • Copper/brass and steel particles contaminated the oil system.
  • The helical sun gear (PN 1-030-192-04) had apparently overheated and all its teeth had been machined off by the three mating planet gears mounted on the reduction gearbox carrier housing assembly. The input gear teeth of the planet gears were extensively damaged, the involutes being filled with smeared metal. Two helical sun gear teeth appeared to have fractured as a result of fatigue crack growth prior to the general destruction of the gear. A gear tooth fragment, matching the remnant of the helical sun gear tooth fracture, was found in the coarse filter screen of the oil pump.
  • The N2 tachometer drive spur gear (PN 1-070-062-04) was loose on its shaft. The nut (PN MS 172237) and nut retainer (cup washer) (PN 1-070-066-01) securing the gear to the shaft were missing from the assembly. The nut was found loose in the accessory drive carrier assembly. The nut retainer, used to lock the nut on the shaft, was found in the scavenge strainer screen of the accessory drive gearbox, with a broken locking tang. Movement of the spur gear resulted in impact and damage to the drive spur gear teeth on the power shaft, reduction gearbox outer housing and No 21 bearing clamping plate.
  • The sleeve bushing of the N2 tachometer drive gear assembly had moved out of its housing and the lower bearing cage had failed. The sleeve bushing retention pin (PN AN122683) missing from the assembly was located in the metal debris subsequent to the teardown inspection. The retention pin hole on the sleeve bushing was not properly located with respect to depth and location.
  • The engine oil pump, mounted on the accessory drive gearbox had seized. The input drive shaft had sheared. A metal sliver (5mm x 2.5mm) jamming a pump impeller blade had caused the seizure. The chip detector was completely covered in particles.
  • Extensive metallic debris was found in the accessory drive gearbox assembly, however, the drive gears and bearings were undamaged. The scavenge strainer screen was blocked with metal debris. Some of the debris was identified as a cup washer from the N2 tachometer drive spur gearshaft and a helical sun gear tooth.
  • The sun gearshaft roller (No. 21) bearing (PN 1-300-082-03M) had completely failed, with no roller elements remaining. A visual examination assessed the failure to be as a result of metal contamination and oil starvation. The power shaft acting as the bearing inner race had been damaged as a result of excessive heat and the skidding rollers of the bearing.
  • The forward compressor ball bearing and aft compressor roller bearing, mounted on the power shaft, suffered damage consistent with oil starvation.
  • The torquemeter boost pump fitted to the engine at the time of the accident was found to be undamaged, correctly assembled and free to rotate.

Reduction gearbox carrier housing assembly inspection

The sun helical and planetary gear is located in the reduction gearbox carrier housing assembly (PN 1-030-340-04). Examination of the GFHO carrier housing assembly following the accident revealed that:

  • The roundness (degree of ovality) of the aft bearing bores was up to 8 times greater than the allowable tolerance of 0.001 inches. The concentricity or alignment of the small bearing (aft) bores with the large bearing (front) bores was found to be up to 25 times greater than the allowable tolerance of 0.001 inches.
  • The carrier housing large bearing (forward) bores were within tolerances.
  • The lack of parallelism between the front and rear plates was found to be up to 7 times greater than the allowable tolerance of 0.001 inches.
  • The bores displayed evidence of fretting damage.
  • The carrier assembly did not have a vendor manufacturing code (required for civil certified components) etched into its surface.

Engine maintenance records recovered by the Transportation Safety Board of Canada, indicated that repairs at the last engine overhaul included the chrome plating and grinding of the six bearing bores of the carrier housing assembly in accordance with the T53 overhaul manual. The concentricity and roundness of the front and rear bore holes of the carrier housing assembly were within limits at the time of the overhaul.

ELT and mobile telephone

After the accident both ELTs carried in the aircraft were found to be switched off. The Narco ELTIO which should have been selected to ARM in compliance with company policy, had the capacity to be activated by crash impact if ARM had been selected. Both survival beacons were found to be capable of normal operation after the accident.

The pilot had access to a mobile telephone fitted to the helicopter. However, even if he had been able to reach it he would not have been able to use it to alert authorities of the accident because the battery had separated from the telephone during the accident. When a serviceable battery was subsequently fitted, the telephone operated normally. The telephone installation was also connected to the aircraft power supply. Inspection of the aircraft indicated the power supply plug had been pulled from the telephone in the accident. Also, severe impact damage to the helicopter's nose area had severed one of the aircraft electrical cables at its point of attachment to the battery relay.

Flight following

Two very high frequency (VHF) radios were fitted to the aircraft for flight following with air traffic services. However, the pilot elected not to use these radios for monitoring of the flight by Airservices Australia. Instead he contacted the DCNR airdesk radio operator and advised of his departure time. The radio he used for the call was provided by DCNR to allow communications on the Victorian public sector mobile radio network (SMR). This equipment was not compatible with the aviation communications network. The pilot used the "trunked" function of the SMR equipment, whereby communications could only be heard by the person transmitting and the person at the specific station the pilot was calling.

The airdesk operator provided "flight following" for the flight. Under the DCNR monitoring system, the pilot was required to make radio contact with the operator at least once every 30 minutes. Following the departure call from Cockatoo, the airdesk operator received no further calls from the pilot. At 1720, the airdesk operator called the helicopter by radio and also by telephone but received no response. At 1725 the airdesk operator contacted the Benalla rappelling crew which was expected to train with the helicopter in the next day or so. A crewman advised that he had called the pilot on the trunked radio at 1636, to ask when the helicopter was expected to arrive at Benalla. The pilot's response was that he would arrive in about 35 minutes (1711 ESUT).

Search and rescue

At 1736 the DCNR airdesk operator contacted Melbourne Flight Service to establish if the pilot of GFHO had transmitted any flight details to Airservices Australia. The Flight Service operator advised that no radio calls had been received from the pilot. At 1802 the DCNR operator advised Melbourne Flight Service that the helicopter was missing. The Flight Service operator in turn relayed the information to the Melbourne Search and Rescue officer. The uncertainty phase of search-and-rescue (SAR) procedures was activated at 1806. Unsuccessful checks to locate the helicopter were made by SAR staff. At 1840 the alert phase was activated. At 1919 the distress phase was activated, 2 hours and 8 minutes after the pilot's estimated time of arrival at Benalla. Search activities continued throughout the night. By the morning of 14 December a large-scale search was under way with 24 helicopters and seven fixed wing aircraft used in the search.

By 1822, on the previous day, the Australian company operating the helicopter had dispatched a helicopter to search for the missing Bell 205. The search pilot estimated that GFHO could have been somewhere in the Marysville area when 35 minutes flight time from Benalla, so he tracked direct to Marysville to commence the search and continued searching while monitoring the ELT distress frequency until 2048, last light being 2101. Marysville is 5.5 km SE of the accident site.

Search co-ordinators and search aircraft focused efforts in the early stage of the search on identifying the source of transmission signals on the distress frequency in the Strathbogie area, about 61 km N of Buxton.

Several people had seen and heard the helicopter minutes before the crash. A couple had heard what was, in hindsight, probably the sound of the helicopter crashing. These people did not hear or see enough to convince them that an accident had occurred. However, they listened to or watched the evening news and when nothing was mentioned about a helicopter accident or a missing helicopter, they did not contact the police. The search authorities made no public media release of the missing helicopter until about 0630 on the morning after the accident. As a result of the media release, police received the first of several public reports of sightings of GFHO between Buxton and Narbethong on the previous evening. Narbethong is 13 km SSW of the accident site. At 0645 police search-and-rescue officers dispatched two units to the Buxton area. At 0916 a police helicopter crew spotted the wreckage of GFHO while searching an area of reported sightings near Buxton the previous day. Most of the sightings were reported to police as a result of the media release. The accident site was 5 km right of the direct track from Cockatoo to Benalla.

Autorotation

Autorotation is the means by which a pilot may safely land a helicopter in the event of no engine power driving the rotors. In single-engine helicopters, loss of drive to the main rotor normally occurs as a result of engine failure. When the engine gearbox failed in GFHO, the engine power output to the main rotor transmission was effectively uncoupled but the engine possibly did not stop immediately. Loss of drive to the main rotors, excluding engine failure, is a very rare event necessitating action by the pilot to effect entry into autorotation in order to maintain rotor RPM. The gearbox failure resulted in metal debris seizing the scavenge oil pump causing overload shearing of the oil pump input shaft; this resulted in sudden loss of engine oil pressure, rapid engine overheating and power loss.

According to the approved flight manual for the Bell 205, the optimum airspeed for an autorotative descent, at a gross weight above 7,500 lb, is 55 to 60 kts. In the case of GFHO, the rate of descent in a stabilised autorotation would have been about 1,900 ft/min. At 35-45 ft above the ground (or in this case above the trees), the pilot flares the helicopter which decreases both the rate of descent and the forward airspeed, followed by levelling the helicopter and increasing collective pitch at about 4 ft. Correct autorotative technique ensures that the helicopter arrives on the ground or contacts the tops of the trees with virtually no rate of descent and very low forward airspeed. For an autorotation into the trees, zero airspeed is preferred at the top of the trees. The ground distance covered from the moment of engine failure to entering a stabilised autorotation to touchdown varies according to the pilot's time to assess and react, airspeed at entry, gross weight of the helicopter, temperature, wind velocity and, in particular, the height above ground or tree tops when the autorotation commences. If the height is greater, so is the potential range.

Evidence at the accident site indicated that GFHO probably had a descent rate of about 500 ft/min and a forward airspeed up to 50 kts when it impacted the trees.

Significant Factors

  1. Misalignment between the helical sun gear and its planetary gears resulted in accelerated wear, high loading and a reduction in fatigue life of the sun helical gear.
  2. Two helical sun gear teeth failed due to fatigue crack growth.
  3. Gear and metal debris lodged in the engine oil pump and seized the pump resulting in loss of engine oil pressure.
  4. Drive to the output gearbox was lost, forcing the pilot to perform an emergency landing.
  5. By not arming the ELT, the pilot diminished his chances of being found quickly after the accident
  6. Vital information was not reported to search co-ordinators for many hours because of a delayed public media release about the missing helicopter.

Analysis

Refuelling spill

During motorised refuelling at Cockatoo, a hose coupling separated, causing jet fuel to spray over the pilot, dampening his clothes. The pilot was seen to wash his hands and face with water before take-off for Benalla. With jet fuel on his clothes, he would have suffered a mild but worsening degree of skin irritation in flight. As the pilot had only flown about 59 km from Cockatoo to the accident site, his flight time would have been about 20 minutes. From the time of refuelling, the time lapse was probably about 30 minutes, by which time he might have been experiencing an uncomfortable burning sensation on his skin. Despite the jet fuel irritation, the pilot's ability to perform an autorotation should not have been impaired significantly.

Engine failure analysis

The Transportation Safety Board of Canada, Transport Canada, and the engine manufacturer assisted in the investigation. The Bureau based the engine failure analysis on the evidence and information presented by these agencies and other parties which included investigation research and analysis in Canada and the United States. The Bureau's findings are based on the most probable engine failure sequence drawn from information received during the investigation.

Helical sun gear

Examination of the remnants of the helical sun gear teeth revealed that two teeth had fractured as a result of fatigue crack growth, prior to the general destruction of the gear. A gear tooth fragment, matching a remnant, was found in the coarse filter screen of the oil pump. A specialist report stated "An examination of the fracture surface revealed that the separation of the gear tooth was caused by fatigue crack growth. The features of the fracture indicate that fatigue cracking initiated in the root radius on the driven side of the tooth. Uniform spalling and the development of cracks in the surface of gear teeth are caused by the high alternating contact pressures created during the meshing of the gears transmitting high loads. The recovered section of the gear tooth showed no evidence of abnormal heating. The general condition of the section of gear tooth is consistent with operation in the presence of lubrication." This indicated that the fatigue failure of the helical sun gear teeth preceded the oil pump failure. The overheat condition was considered to be secondary damage caused by loss of lubrication.

Reduction gearbox carrier housing assembly

Examination of the carrier housing assembly revealed large out-of-tolerance ovality and concentricity between the front and rear bearing bores. At the request of BASI, and under its direction, the manufacturer analysed the effects of a planetary gearshaft misalignment to address bore mis-machining. The manufacturer concluded that the time to failure correlated with the level of gear mesh misalignment found.

Repairs to the six bearing bores of the carrier housing assembly were carried out at the last engine overhaul. Examination of documentation relating to this procedure indicated that the concentricity and roundness of the front and rear bore holes of the carrier housing assembly were within limits following the repair. The errors in ovality, concentricity and parallelism found after the accident were therefore considered to be as a result of forces produced during the engine failure sequence and during disassembly of the engine following the accident.

The engine manufacturer examined the documentation relating to this procedure and considered that bearing bore true position errors may have been introduced during the grind/plate process as a result of the tooling fixture that was used.

The engine manufacturer confirmed that the carrier housing assembly in GFHO was not approved for use in civilian T53 engines. However, this was not considered to have contributed to the failure of the engine.

N2 tachometer drive spur gear assembly

The locking tang of the nut retainer on the assembly was found to have fractured due to overload. This may have occurred during assembly of the spur gear at the last overhaul. Wear marks were evident around the indentation that locked the nut retainer onto the nut. Cup washer failures are known and the manufacturer has since addressed the assembly procedures.

Oil pump

The metal jamming the oil pump was identified as case hardened material, indicating that it was gear material. The size and shape of the material suggested that it was a chip of a gear tooth.

Engine drive failure

BASI was unable to satisfactorily determine the primary event leading to the engine failure. From the information available, two possible engine-drive failure sequences were identified:

Sequence 1
  • The locking tang of the nut retainer on the N2 tachometer drive assembly fractured due to overload, possibly during assembly at the last engine overhaul.
  • The nut on the gearshaft lost torque during engine operation and gradually backed off the shaft with the cup washer. The nut and cup washer fell into the inlet housing.
  • The loose N2 tachometer drive spur gear resulted in wear on the threads of the gearshaft, damage of the reduction gearbox outer housing and damage of the No. 21 bearing clamping plate.
  • Debris from the wear and damage of the components entered the No. 21 bearing. Damage to the bearing resulted in misalignment of the sun gearshaft with its mating planetary gears.
Sequence 2
  • Repairs to the reduction carrier assembly bearing bores at the last engine overhaul resulted in planet gear bearing bore true position errors. This resulted in misalignment of the sun gearshaft with its mating planetary gears. Vibratory forces resulted in the backing off of the N2 tachometer drive nut and cup washer from its shaft.
Common sequence
  • Misalignment between the planetary and sun gear resulted in accelerated wear, high loading and a reduction in fatigue life of the sun helical gear. Two gear teeth from the sun helical gear fractured due to fatigue crack growth resulting from the abnormal loads.
  • Abnormal loading resulting from the misalignment of the loose N2 tachometer drive spur gear caused the bearing sleeve to work out of the accessory carrier and damage to gear teeth on both the N2 spur gears.
  • A tooth chip from the sun helical gear or the N2 drive spur gear was carried with scavenge oil and lodged in the engine oil pump, jamming an impeller. This caused the overload failure of the oil pump input drive shaft, halting oil supply and scavenging.
  • Loss of oil pressure resulted in high temperature damage to the forward and aft compressor bearings and No. 21 bearings, and to the reduction gearbox carrier assembly gears and bearings.
  • Lack of lubrication and misalignment of the sun helical gear resulted in the complete stripping of its gear teeth.
  • The abnormal loading on the gear assembly deformed the rear reduction gearbox carrier and its bearing bores.
  • Failure of the sun helical gear resulted in loss of drive to the output gearbox and no engine power being transferred to the main transmission.

Lubrication system contamination troubleshooting

On 29 Sep 1995, it was reported in the journey log that the airframe paper filter contained copper-coloured metal contamination. According to the maintenance organisation, they suspected a problem with the accessory gearbox and replaced it at this time. Additionally, following discussions with the engine repair shop it was assessed by the maintainer that the N2 torquemeter boost pump could also have been responsible for the brass contamination found in the engine filter. It was decided that the torquemeter boost pump would be changed following shipment to Australia.

Subsequent inspection of the removed accessory gearbox indicated that it was not responsible for the oil contamination. The torquemeter boost pump was reportedly replaced prior to commencement of flying operations in Australia and when inspected was found to have been mis-assembled. This had resulted in loss of drive to the boost pump rotors and generation of metal from a brass bearing bush. It was considered that the brass in the engine filter was from the brass bearing. The operator provided this information after the accident and at that time it was not entered in the aircraft maintenance logbooks.

Maintenance records did not report that the manufacturer's recommended lubrication system contamination troubleshooting procedures as detailed in the T53-17A maintenance manual were followed. The metal found in the engine filters may have been an early warning that the engine failure was imminent. The engine manufacturer believed that if the maintenance manual procedures had been followed, the engine could have been flagged for repair or possible removal prior to the accident.

The operator considered that the intent of the requirements in the engine manufacturer's troubleshooting procedures was carried out. Through systematic checks and inspections the source of the brass metal contamination was determined to be the torquemeter boost pump. By replacing the defective part and carrying out ground runs the operator considered that standard procedures were followed.

The failure sequence may have occurred over such a short period of time, that there was little forewarning of the impending engine failure. No reports of chip lights illuminating were entered in the maintenance logs following the aircraft's arrival in Australia.

Autorotation

The reason the helicopter retained substantial forward speed and rate of descent when it impacted the treetops could not be determined.

Search and rescue

The fact that the ELTIO was off and not switched to the preferred selection of ARM, seriously diminished the pilot's chances of being found quickly after the accident.

Police found the accident site largely in response to witness sighting reports received after the media release about the missing helicopter. The delay in the media release may have diminished the pilot's chances of survival.

Summary

The Canadian registered helicopter C-GFHO, along with a pilot and maintenance engineer, had recently been shipped to Moorabbin Airport from Canada. It had been partially dismantled for transport to Australia and was re-assembled at Moorabbin Airport during November 1995. It was to have been part of the fire-fighting service to be operated during the fire season by the Victorian Department of Conservation and Natural Resources (DCNR). For the fire-fighting role, the helicopter had the capability to ferry fire crews and to be used for rappelling operations. It was also equipped with a belly tank for fire bombing. DCNR had planned to base the helicopter at Benalla for the fire season. Some initial testing and training had been done with the aircraft after re-assembly, but it had not formally started fire-fighting operations.

Early on the afternoon of 13 December 1995, the pilot ferried the aircraft from Moorabbin Airport to Cockatoo, 35 km ENE of Moorabbin. During the afternoon it was used at Cockatoo to assist in the training of volunteer fire fighters. During this training the pilot gave familiarisation briefings to the volunteers, including demonstrating the helicopter emergency locator transmitters (ELTs). Two were carried; one was a marine survival beacon, and the other was a Narco ELTIO designed for aviation use. Subsequently, during start-up for a demonstration flight, the pilot discovered that the ELTIO was inadvertently switched on and transmitting the distress signal. He turned the ELT off but did not arm it for impact activation.

On completion of the training exercise, the pilot departed Cockatoo at 1623 ESUT for Benalla, to position for the start of operations. About 5 km S of Buxton, 105 km SSW of Benalla, the engine gearbox failed resulting in loss of drive from the engine to the main transmission. The pilot performed an autorotative descent but failed to reach a clearing. After initial tree impact, the helicopter travelled 60 m horizontally before ground impact. The trees were approximately 25 m high and the terrain was undulating. The helicopter was destroyed in the accident.

The wreckage was difficult to see from the air because of the tree canopy. Despite a subsequent search, the helicopter was not located until about 0916 ESUT on 14 December, approximately 16.5 hours after the accident.

Occurrence summary

Investigation number 199504205
Occurrence date 13/12/1995
Location 5 km S Buxton
State Victoria
Report release date 01/01/1999
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Forced/precautionary landing
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Bell Helicopter Co
Model 205
Registration C-GFHO
Serial number C-GFHO
Sector Helicopter
Operation type Private
Departure point Cockatoo, VIC
Destination Benalla, VIC
Damage Destroyed

Cessna A188B/A1, VH-HYN, Home Hill (ALA), Queensland

Summary

FACTUAL INFORMATION

Sequence of events

The pilot had been spraying cane fields near the accident site. The aircraft was observed flying towards an airstrip about 1 km away where a spray hopper was positioned on a trailer. At about 0650 hours, the aircraft was seen flying straight and level towards the airstrip. The aircraft was then seen to strike powerlines, roll inverted and impact the ground. The aircraft came to rest inverted. The aircraft had impacted two high-voltage powerlines approximately 17 m above ground level.

Damage to aircraft

The fuselage forward of the wing leading edge was destroyed and the engine was forced rearwards into the hopper. The main cockpit structure was intact, and the seat and harness were undamaged. The windscreen was broken but the windscreen frame was intact. The instrument panel was badly damaged by impact from the pilot. The fuselage rear of the cockpit area was creased but the tailplane and fin were intact, suffering only minor damage. The right wing outboard leading-edge section was severed by powerline contact. The aircraft severed two wires. The top aerial earth wire consisted of three strands of 2.55mm aluminium conductor wound around four strands of 2.5mm steel conductor, and a 66-kilovolt cable consisted of 30 strands of 2.55mm aluminium conductor wound around seven strands of 2.5mm steel conductor.

Meteorological information

The weather was fine at the time of the accident, with a light south-easterly wind.

Wreckage examination

There were no mechanical defects discovered with the airframe or the engine which may have led to the development of the accident. The seat harness was found undone immediately after the accident and did not exhibit any signs of stress as would have been expected after such impact.

Tests and research

Considerable research and testing was carried out to ascertain if there was a possibility of the seat harness being released by impact forces. Testing of the harness and buckle was conducted at Crash lab, the Roads and Traffic Authority of New South Wales test and research centre, which specialises in dynamic testing of safety harness.

Initial examination of the harness found there were no signs of severe loading on the buckle, adjusters, anchors or webbing. However, load bearing marks on the webbing of the lap and shoulder sections of the harness were evident following dynamic testing of the harness.

Dynamic testing of the aircraft safety harness was conducted to test the overall integrity of the harness and also to investigate the possibility of the over-centre buckle being inadvertently released by the occupant's abdominal region during a dynamic impact. The dynamic test demonstrated that the harness was able to restrain the anthropomorphic test dummy without evidence of abnormal distortion, separation or damage to the harness webbing and components. The test also demonstrated that the over-centre buckle did not release during dynamic impact, when correctly latched.

The testing indicated that the aircraft safety harness was not correctly fastened at impact. The possibilities were, therefore, that the harness was not worn at all by the pilot, that the harness was worn but the over-centre buckle was not correctly latched (in other words, the detent mechanism was not fully engaged), or that the buckle was inadvertently unlocked during the flight or accident sequence by clothing or arm contact with the latch.

ANALYSIS

Given that the powerline was the largest and most obvious in the area, it is difficult to understand why the pilot failed to avoid it. The possibility of the low angle of the sun momentarily dazzling the pilot was considered but this is unlikely due to the aircraft being in a right turn and heading in a south-easterly direction shortly before impact. Some witnesses described seeing what appeared to be puffs of smoke from the engine seconds before the aircraft hit the powerline. The aircraft was fitted with a smoke generator so the pilot could assess the wind drift. This could occasionally emit puffs of smoke due to small quantities of oil leaking into the system.  The possibility of an engine malfunction distracting the pilot at a crucial moment and diverting his attention to inside the cockpit cannot be discounted; however, there was no evidence found to support this theory.

Examination and testing of the seat harness led to the conclusion that the harness was not fastened at impact. The harness was not fitted with an inertia reel. The possibility that the pilot momentarily undid the harness to retrieve an item from the cockpit floor was considered. However, this is unlikely as the floor cannot be reached even with the harness undone.

SIGNIFICANT FACTORS

  1. The aircraft struck a powerline, causing loss of control.
  2. The pilot's seat harness was unfastened prior to or during the impact sequence for reasons unknown.

SAFETY ACTION

Action by the Civil Aviation Safety Authority

The Civil Aviation Safety Authority had previously issued Airworthiness Directive (AD) Restraint 7 Amendment 2 for this safety harness buckle [MS22013 (ASG)] in response to industry concerns about inadvertent buckle release during aerobatics.

Action by the Bureau of Air Safety Investigation

As a result of this occurrence, the Bureau of Air Safety Investigation issued Safety Advisory Notice (SAN) 960153 to the Civil Aviation Safety Authority. The safety deficiency identified was:

"AD restraint 7 Amendment 2 for safety harness buckle MS22013 (ASG) refers to utility and acrobatic category aircraft only.  The AD should address all categories of operations."

Occurrence summary

Investigation number 199503986
Occurrence date 27/11/1995
Location Home Hill, (ALA)
State Queensland
Report release date 18/02/1997
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Wirestrike
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Cessna Aircraft Company
Model 188
Registration VH-HYN
Serial number 18803046T
Sector Piston
Operation type Aerial Work
Departure point Home Hill, Qld
Destination Home Hill, Qld
Damage Substantial

Robinson R22 Beta, VH-JNA, Carse'Ogowrie Station, Queensland

Summary

The crews of two helicopters had been engaged in survey work. On the morning of the accident, the second helicopter became unserviceable. The pilot and passenger, in conjunction with the pilot of the grounded helicopter, decided to continue on their own. About 45 minutes after commencing the flight, the helicopter flew up a dry creek line and struck a high-voltage single wire powerline. The line severed the flying controls at the mast. All control was then lost and the helicopter crashed into the dry creek bed.

When electrical power was lost at the cattle station homestead, search parties were sent in both directions along the powerline. The wreckage of the helicopter was found about 45 minutes after the power was lost.

The span of the SWER (single wire earth return) line struck by the helicopter was 490 m and was strung between two hilltops. The point of impact was approximately 40 m above the creek bed and about 20 m above the general tree canopy. This was the pilot's second day at the station. He was not familiar with the area south of the homestead which included the crash site.

Significant factors

The following factors were considered relevant to the development of the accident:

  1. The pilot was flying the helicopter at low level in a survey/mustering operation.
  2. The second helicopter which had been used for lookout duties was unserviceable.
  3. The pilot was unfamiliar with the area.
  4. He did not see the SWER line in time to avoid a collision.
  5. Control of the helicopter was lost when the wire cut control rods.

Occurrence summary

Investigation number 199503814
Occurrence date 14/11/1995
Location Carse'Ogowrie Station
State Queensland
Report release date 10/05/1996
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Collision with terrain
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Robinson Helicopter Co
Model R22 Beta
Registration VH-JNA
Serial number 971
Sector Helicopter
Operation type Aerial Work
Departure point Carse'Ogowrie Station, QLD
Destination Carse'Ogowrie Station, QLD
Damage Destroyed

Piper PA-28R-200, VH-YAB, 14 km west-north-west of Childers, Queensland

Summary

FACTUAL INFORMATION

At 0721 EST, while taxiing for take-off at Coolangatta, the pilot informed the aerodrome controller that he intended to fly along the coast at 500 ft. He had not submitted a flight plan and did not require search and rescue services.

The early part of the flight to Noosa was without apparent difficulty. The aircraft was last observed by radar at 0820, crossing the coast on a north-westerly track south of the Wide Bay Restricted Area. Radar returns indicated that the aircraft was at 2,500 ft at the time. The pilot did not communicate with the Brisbane Flight Service unit.

At about 0907 witnesses on the ground heard what they believed was aircraft engine noise, which was varying in intensity, followed by a loud bang. A short time later several large pieces of aircraft were seen to fall from the low cloud base, followed by a shower of lighter material.

The Area 40 weather forecast covering the period from 0300 to 1800 on 26 October 1995, indicated wide-spread rain from stratiform, layered cloud, with a base below 1,000 ft. A clearing change, gradually moving east, was expected at the coast about midday. Pilots who flew in the area at about the time of the accident reported that the cloud mass was quite thick, with a base at about 600 ft and tops to 14,000 ft in places. Witnesses on the ground said that the cloud base was unbroken at about 500 ft above ground level. No thunderstorms were reported in the area. An Area 40 forecast was available to the pilot before the flight commenced but it is not known whether he obtained one from the Brisbane Briefing Office.

Examination of the wreckage found that the left wing had failed in overload and had separated from the fuselage.

The remainder of the aircraft structure then rapidly disintegrated. There was no evidence of an in-flight explosion. The landing gear was found in the extended position.

The validity of the aircraft's Maintenance Release expired on 20 October 1995.

The pilot was the owner of the aircraft, and he used it almost exclusively for transport between the Gold Coast and Rockhampton where he had business commitments on a semi-regular basis. On the day of the accident, he had business scheduled in Rockhampton. He did not hold an instrument rating but did hold a night visual flight rules (NVFR) rating. His logbook showed that he had completed his endorsement training in the aircraft in October 1990. He had not undertaken a biennial flight review within the two years prior to the accident.

In 1990 the pilot underwent heart bypass surgery. Since the operation he had regained his Class 2 medical certificate and was allowed to exercise the privilege of his pilot's licence. The post-mortem examination revealed the presence of ischaemic heart disease, a deficiency of blood in part due to functional constriction or actual obstruction of a blood vessel.

ANALYSIS

Weather and Flight Planning

Both the Area 40 forecast and actual weather reports indicated that it was unlikely that the pilot could have completed his flight in visual meteorological conditions.

The Pilot

Examination of his logbook showed that the pilot first flew VH-YAB during training for a Constant Speed (Propeller) and Retractable Gear endorsement in October 1990. In September 1991 he obtained a NVFR rating. The last log-book entry was dated March 1995. However, a detailed, current notebook recorded his flying activities. He had noted 45 flight hours in VH-YAB since March 1995, mostly on flights to and from Rockhampton.

The NVFR rating is not regarded by the Civil Aviation Safety Authority (CASA) as an instrument rating; however, the pilot would have gained limited instrument flying experience during his training for the rating.  A passenger on an earlier flight said that on one occasion they were caught above cloud. The aircraft entered cloud and seemed to be out of control for a period of time.

The post-mortem examination report revealed the presence of ischaemic heart disease. The report found that there may have been a cardiac episode prior to the crash which affected the pilot. With the degree of ischaemic heart disease found, any relative hypoxia of the myocardium might have precipitated a rapid and/or irregular rhythm, bringing about left ventricular failure. The report noted that anxiety with a rapid heart rate might trigger such a sequence. A specialist report from the Directorate of Aviation Medicine, CASA, endorsed the findings of the post-mortem examination report, adding that unfavourable in-flight conditions may have brought on some degree of myocardial ischemia through anxiety.

Aircraft Operation and Crash Site Examination

The crash site is situated on the direct track between Maroochydore and Gladstone. Examination of the aircraft's gyro flight instruments confirmed that they were functioning up to the point of breakup. The Piper Auto control 111 automatic pilot was switched on.  A Magellan NAV 1000 PLUS (Marine) Global Positioning System (GPS) had been connected to the aircraft's electrical system. All GPS data was lost due to the loss of aircraft power supply and its battery pack backup. However, it is possible that the pilot had the relevant data entered in the GPS receiver and was flying along the route.

The altitude at which the aircraft broke up could not be determined. Examination of the recorded radar tapes did not show the aircraft. The Mt Alma radar near Rockhampton is a monopulse secondary surveillance radar which relies on an operating aircraft secondary surveillance radar transponder. The pilot may have switched his transponder off, or the aircraft may have been operating below the radar horizon. Interpolation of radar coverage maps indicated that the radar horizon is approximately 6,000 ft over the crash site.

Witnesses described the engine sound as varying before the aircraft broke up. The varying engine noise was probably due to the doppler effect as the aircraft, relative to the witnesses, continually turned away and towards them in a downward spiral.

The aircraft had an automatic gear extension system which lowers the landing gear when the speed drops below about 90 kts. That the landing gear was down and locked could indicate that the air speed dropped below normal cruise speed some time before the breakup, or that the gear was deliberately lowered.

CONCLUSIONS

Findings

  1. The aircraft was overdue for maintenance but was otherwise serviceable for flight as far as could be determined.
  2. The pilot was not trained or rated for flight under instrument flight rules.
  3. On a previous flight, the pilot had flown into cloud and probably lost control of his aircraft.
  4. The pilot had scheduled business in Rockhampton on the day of the accident.
  5. The weather was unsuitable for visual flight.
  6. The pilot continued the flight without visual reference to the ground or horizon.
  7. The pilot was suffering from ischaemic heart disease and may have been incapacitated.
  8. The pilot lost control of the aircraft.
  9. The aircraft was overstressed and as a result broke up in flight.

Significant factors

  1. The pilot was unable to continue visual flight rules flight along the coast as planned and entered cloud, probably relying on his autopilot and GPS to aid him in control and guidance of his aircraft.
  2. Control of the aircraft was lost by the pilot either through disorientation, incapacity, or a combination of both.

Occurrence summary

Investigation number 199503601
Occurrence date 26/10/1995
Location 14 km west-north-west of Childers
State Queensland
Report release date 13/08/1996
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category In-flight break-up
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Piper Aircraft Corp
Model PA-28
Registration VH-YAB
Serial number 28R-35228
Sector Piston
Operation type Business
Departure point Coolangatta, QLD
Destination Rockhampton, QLD
Damage Destroyed

Robinson R22 Beta, VH-HLJ, Kilclooney Station, Queensland

Summary

1. FACTUAL INFORMATION

1.1 History of the flight

The pilot had commenced mustering at Kilclooney Station at about 0700 EST. A refuelling stop was made at about 0930 when the mustering operation had been completed. After refuelling, the pilot took off and returned to the homestead, which was about 5 minutes flying time away, intending to collect his swag and the helicopter canopy cover and then return to his home base at Greenvale, 76 km west of Kilclooney. The pilot phoned his wife at about 1045 to say he was departing Kilclooney. At about 1050 the power supply to the homestead failed. The homestead was unattended at the time. At 1330 the company chief pilot reported to Brisbane Search and Rescue (SAR) the aircraft had not arrived at Greenvale. At 1348 the Brisbane Area Approach Control Centre (AACC) co-ordinator advised SAR that an emergency locator transmitter (ELT) signal had been heard by an overflying aircraft. The Queensland Emergency Services helicopter was then tasked to conduct a search in the area where the beacon was heard. At 1506 the wreckage of the helicopter was located at Kilclooney Station.

The helicopter had collided with a single 19-kilovolt powerline located near where the helicopter had been parked overnight. He had apparently landed near the homestead, to collect the swag which was known to be on the back of a vehicle, and then repositioned the helicopter to the parking area to pick up the canopy cover.  Two parallel wires

15 metres apart were strung from poles near the homestead and passed alongside the parking area in a southeast-northwest direction.

1.2 Impact information

It is probable that as the helicopter was approaching the parking area from the south, the left skid passed under the second wire which had a span of approximately 150 metres. The helicopter travelled a short distance before impacting the ground in a steep nose-down attitude and caught fire. The three-strand 12-gauge steel wire did not break and was trapped under tension by the wreckage for some time. The left skid was thrown clear of the fire when it became detached by heat and the wire separated from the wreckage. The wire was substantially stretched and was within 4 metres above ground level after becoming detached from the wreckage.

1.3 Pilot in command

The pilot was correctly licensed and endorsed and appeared to be in good health immediately prior the accident.

1.4 Meteorological information

Station personnel reported that the weather was fine with a moderate northerly wind at the time of the accident.

1.5 Wreckage examination

The cabin area forward of the firewall was completely destroyed by fire. The engine suffered substantial fire damage, and all engine accessories were damaged beyond the point where the serviceability of these items could be assessed. The ELT was a fixed installation in the engine bay and was destroyed by fire, it was of the type that complied with TSO C91. No mechanical failures or defects were discovered with the engine which would have prevented it from operating normally. The tail boom was separated from the main wreckage and remained clear of the fire. The tail rotor and tail rotor gearbox appeared undamaged, indicating that a steep nose-down impact had occurred.

2. ANALYSIS

The wind direction would have required an into-wind approach to be made over two wires which were about 15 metres apart. The approach over the second wire would have to be steep to achieve a touchdown near the fuel drum where the canopy cover was located and would therefore have taken the helicopter close to the second wire. During the accident sequence the helicopter actually struck the drum. Why the helicopter struck the wire could not be determined, but it is probable that the helicopter was capable of normal operation up to the time of the accident. The canopy cover was on the ground beneath an upright 200-litre fuel drum, located about 10 metres from the powerline. The helicopter was probably previously parked in this particular position as the pilot did not want to frighten horses in an adjacent paddock.

3. CONCLUSIONS

3.1 Findings

  1. The pilot was correctly licensed and fit to perform the flight.
  2. There were no mechanical defects discovered which may have contributed to the accident.
  3. The helicopter had been previously parked in close proximity to a single strand powerline and was being manoeuvred to land at this position to allow the pilot to collect the helicopter canopy cover.
  4. The wind direction required an approach from south to north over the top of the powerline.
  5. The helicopter struck the powerline.

3.2 Significant factors

  1. The aircraft was being manoeuvred in close proximity to a single-wire powerline.
  2. The pilot failed to see and avoid the powerline.

Occurrence summary

Investigation number 199503772
Occurrence date 10/11/1995
Location Kilclooney Station
State Queensland
Report release date 31/07/1996
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Collision with terrain
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer Robinson Helicopter Co
Model R22 Beta
Registration VH-HLJ
Serial number 0734
Sector Helicopter
Operation type Aerial Work
Departure point Kilclooney Station, QLD
Destination Greenvale, QLD
Damage Destroyed

American Aircraft AA-5B, VH-WPY, Mt Warning, New South Wales

Summary

The pilot hired the aircraft with the stated intention of conducting practice circuits at Archerfield. When he taxied, he told the Surface Movement Controller that he was proceeding to the (Archerfield) Southern Training Area. The aircraft departed the circuit area at 0927 EST.

At about 0955, a witness near Mt Warning heard an aircraft engine operating at high rpm followed by the sound of impact. Later an aerial search found the fragmented and burnt wreckage of an aircraft at the base of a near vertical cliff on the north face of Mt Warning. The aircraft had impacted head on, near the geometric centre of a large triangular shaped cliff face. The weather at the time was fine with a clear blue sky and light winds.

On the basis of information received concerning the circumstances of this occurrence, the Bureau has discontinued its investigation.

Occurrence summary

Investigation number 199503513
Occurrence date 24/10/1995
Location Mt Warning
State New South Wales
Report release date 22/11/1995
Report status Final
Investigation type Occurrence Investigation
Investigation status Completed
Mode of transport Aviation
Aviation occurrence category Miscellaneous - Other
Occurrence class Accident
Highest injury level Fatal

Aircraft details

Manufacturer American Aircraft Corp
Model AA-5
Registration VH-WPY
Serial number AA5B-1146
Sector Piston
Operation type Private
Departure point Archerfield, QLD
Destination Archerfield, QLD
Damage Destroyed