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DEFENCE FLIGHT SAFETY BUREAU

ADF Propulsion Symposium

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PC9 Engine Failure near Beermullah, WA – 2 Nov 17

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Event Sortie

Perth region

PC-9A

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Power Control Lever

EFCU Toggle

Engine control

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~ 9 sec

Event

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Gingin training area

Recovery

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Overhead Beermullah Airstrip

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Approach into Beermullah

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Touch down and roll

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A23-001 at Beermullah

On-site investigation

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Cowling and LH Exhaust stub

Blade fragments

RH Exhaust stub

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Outlet (stubs removed)

Rear face of PT2 Rear face of PT2

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CT Boroscope

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FWD

PT6A-62 Engine

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Vector Aerospace, Brisbane

Engine tear-down

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Combustion Chamber Liner

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Compressor Turbine Blades

Metallic spatter

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Example CT blade

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CT blade microscopy

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Thermocouples

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Power Turbine 2 Blades

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Analysis

PT2 Blades

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PT2 Blade with delaminating metallic spatter

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EFCU Lever, Fuel Control Unit

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Fuel Control Unit (FCU) Manual OverRide (MOR) Lever

MOR Mechanism

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Cockpit Voice Recorder

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CVR, FDR and ELU Sync

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“Snapback”

MOR Lever (Brown), EFCU Actuator (Blue), Mounting Rod (Yellow)

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Fast Actuator

EFCU Actuator

~13% exceedance

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~13% exceedance

Fuel Flow

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Fuel Air Ratio

27% exceedance

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Surge

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Surge and Stall Identification

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Interplay of factors

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Use of EFCU

Low mass flow (airspeed/altitude)

Fast EFCU Actuator

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Year Question Response

1998 OEM Letter: Recommends against routine use of the EFCU.

Nil

2005 ASOR Recommendation: investigate the frequency with this emergency system is used in every day training flights, whether it was designed for such a purpose and if so what sort of maintenance schedule is appropriate

Rejected

2010 ASOR: The use of airborne EFCU for training at 2 FTS be reviewed for compliance with DI (AF) OPS 3-1, which states that Airborne Emergency Training is to be conducted only where there is a clear benefit and minimum risk

WASO is developing an EE500 template for recording EFCU use.

2010 SPO Investigation: 70% of failures world wide occurred with RAAF aircraft. Feedback from Pilatus was that the EFCU should only be for emergency use and not training.

Log use of the EFCU for training purposes, to assist in determining the number of failures

2014 OEM Letter: Recommends against routine use of the EFCU.

Nil

History: Routine use of EFCU

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Recommendations

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• Beermullah airstrip maintenance (enduring) • Other emergency airstrip maintenance (enduring) • Use of airstrips in planning • 2FTS SI update (airstrip layout)

• EFCU Actuators, ensure within specification

• Non-emergency use of EFCU Toggle

• Awareness regarding surge ‘risk-factors’ • Awareness regarding EFCU Toggle + Surge scenarios

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Key learning outcomes

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• ASRs: Actions must address recommendation

• Using equipment outside of intended use. Make sure the risk has been assessed and accepted

• Question organisational norms

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Questions

Comments