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Aviation safety reports, made easier to study

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January 12, 2024 · Eurocopter AS 350 B2 · N204TX

Spofford, TX

Overview

Report Status
Final with probable cause
Event Type
Accident
Date
January 12, 2024
Injury Outcomes
2 injuries (2 minor injuries)
Location
Spofford, TX
Aircraft
Eurocopter AS 350 B2 (2003)
Tail Number
N204TX
Operator
Texas Department of Public Safety
Injuries
Minor
Aircraft Damage
Substantial
NTSB Number
CEN24LA088

The flight crew had competed their aerial observation and were enroute to the destination airport. While enroute, the pilot felt a violent yaw to the right, saw the engine low pressure annunciator illuminate, and heard the low rotor horn. After the engine lost power, the pilot transferred the flight controls to the copilot, who performed an autorotation and landed the helicopter in a brush-covered field. Postaccident examination and testing of the engine revealed that the engine’s fuel control unit (FCU) control lever arm was broken. Metallurgical examination of the control lever arm revealed it had failed due to a fatigue fracture which resulted in a loss of fuel control to the engine and fuel starvation.

NTSB Probable Cause

The fatigue failure of the fuel control unit control lever arm, which resulted in fuel starvation, and a loss of engine power.

Full Narrative

On January 11, 2024, at 1900 central standard time, a Eurocopter AS 350 B2, N204TX, was substantially damaged when it was involved in an accident near Spofford, Texas. The pilot and copilot received minor injuries. The helicopter was operated as a public aircraft conducting an aerial observation flight. During the flight, the pilot decided to return to his base when he saw that the fuel gauge indicated 20% fuel remaining. The engine instruments did not indicate any anomalies. The pilot then felt a violent yaw to the right, saw the engine low pressure annunciator illuminate, and heard the low rotor horn. The copilot asked the pilot what happened, and the pilot said that they had lost the engine. The pilot transferred controls to the copilot after the rotor rpm returned to the normal operating range. The copilot then performed an autorotation and landed the helicopter in a brush-covered field. The helicopter sustained substantial damage to the tail boom and main rotor. The engine was placed in a test cell for a postaccident engine run. During the run, the engine would not accelerate past 45% gas generator speed (Ng). The FCU, part number 0164851320, serial number 937B, was removed, and another FCU was installed. The engine then operated normally during the second test run. The FCU from the accident airplane was bench tested. The test revealed that it could not achieve maximum fuel flow per the test specifications. The FCU was then disassembled, and the FCU control lever arm, part number 0164042540, was found broken. National Transportation Safety Board Materials Laboratory examination of the broken FCU control lever arm revealed a crack with fine fatigue striations, typical of high-cycle or low-load fatigue. Outside of this crack, the fracture surface exhibited dimpled rupture, consistent with subsequent overstress fracture in the remaining lever arm. According to the examination report, these features were consistent with the initial fracture of the lever arm through about two-thirds of the cross-section. This crack or fracture edge of this early fracture then initiated fatigue cracking at multiple sites. Once the fatigue cracks had propagated deep enough, the remainder of the lever arm cross sections fractured via overstress.

Flight

Event TypeAccident
Event Time19:00 CST
Nearest Airport0nm
Flight Plan FiledNone
Flight Plan ActivatedNo
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftEurocopter AS 350 B2
Tail NumberN204TX
Aircraft CategoryHeli
DamageSubstantial
OperatorTexas Department of Public Safety
Engines1
Engine TypeTurboshaft
Engine DetailsSafran Aircraft Engines · Arriel 1D1 · Turboshaft · 712
Seats4

People & Injuries

Injury Summary2 injuries (2 minor injuries)
Fatal0
Serious0
Minor2
Uninjured0
Total2
Crew 1Age 39 · Second Class · Minor
Crew 2Age 54 · Second Class · Minor

Conditions

ConditionsVMC
LightDark Night
Wind170° @ 8 kt
Visibility10 sm
CeilingNone
Temperature / Dew Point70 F / 14 C
Altimeter29.46 inHg
Observation Time19:15
Weather SourceWFAC

Appendix: Source Data