N357CA

HISTORY OF FLIGHT

On July 10, 2009, about 1927 eastern daylight time, an Ayres Corporation S2R-T34, N357CA, registered to Craft Air Services LLC, operated by Craft Air Service, Inc., crashed in a cornfield near Craig Craft Airport (86NC), Hertford, North Carolina. Visual meteorological conditions prevailed at the time and no flight plan was filed for the 14 Code of Federal Regulations (CFR) Part 91 other work use flight. The airplane sustained substantial damage and the certificated commercial pilot was killed. The flight originated from 86NC about 1907.

The founder and chief pilot of Craft Air Services LLC (chief pilot) flew the accident airplane earlier that day for approximately 14 minutes, and performed spray passes applying water. The only discrepancy he noted was related to the spray nozzles, which were adjusted after the flight.

This was the pilot's first flight in a turbine powered Ayres airplane. Before the accident flight departed, the pilot filled the left fuel tank with Jet A, and added 225 gallons of water to the hopper tank. A witness reported the departure appeared normal and the accident pilot proceeded to make a spray pass over a cornfield located adjacent to the runway. The pilot then proceeded across the street to a large open area without nearby obstructions, and was observed making practice spray runs.

The chief pilot, who was airborne in another airplane spraying chemical near the approach end of the runway at 86NC, noticed the accident pilot returning to 86NC, and asked the pilot if he was landing. The accident pilot responded that he wanted to go back and make a few more passes.

Another individual who heard the accident pilot state he wanted to make a few more passes to, "…get the [feel] of the plane some more" heard the pilot perform 2 or 3 more passes which during the propeller sound during the pull-up and turn maneuver was consistent. During the last pull-up and turn maneuver, the sound from the propeller was not the same at the end of the procedure. He reported typically during a pull-up and turn, the sound starts low then gets louder and at a higher pitch then ends the same way it started. During the last pull-up maneuver the sound "…started low got louder and at a high pitch, like always, but it seemed to stay that way just a moment too long and then I heard one solid lick!" The witness ran to the center of the runway and looked for the crashed airplane but did not see it. He ran to a radio and called for the accident pilot but there was no response. The witness called on the radio to the chief pilot asking him to fly in the area to check on the accident pilot and about 20 to 30 seconds later the chief pilot radioed him to call 911, which he did. The chief pilot landed and both drove in a vehicle near the crash site.

The chief pilot reported that he noted what appeared to be a whisp of rising smoke and simultaneously heard a ground crewmember calling on the radio to the accident pilot, but there was no response. The chief pilot flew his airplane towards the area of the smoke and noted the airplane was inverted in a cornfield.

PERSONNEL INFORMATION

The pilot, age 37, held airline transport pilot, commercial, and certified flight instructor certificates. The airline transport pilot certificate was endorsed with airplane multi-engine land rating, the commercial pilot certificate was endorsed with airplane single engine land, and the certified flight instructor certificate was endorsed with airplane single engine rating. He held a second class medical certificate issued January 27, 2009, with no medical restrictions or limitations. He listed having 10,800 hours total flight time on the application for his last medical certificate. The brother of the pilot estimated his total time was 14,000 hours, and reported he was familiar with flying an airplane equipped with a PT6 engine because he had flown a Cessna 208 (Caravan) airplane. The NTSB Pilot/Operator Aircraft Accident/Incident Report submitted by the operator indicated the pilot's total time in all aircraft for the last 90 days, 30 days, and 24 hours were 250, 75, and 4 hours, respectively.

The pilot began full-time employment with Craft Air Services LLC in late February or early March 2009. The operator reported the pilot had accumulated 250 hours in an Air Tractor AT-301 airplane, which is an agricultural spray airplane equipped with a radial engine. The accident flight was the pilot’s first flight in a turbine powered Ayres airplane.

AIRCRAFT INFORMATION

The airplane was manufactured in 1978 by Ayres Corporation as model S2R-T34, and was designated serial number 6000. At the time of manufacture, it was equipped with a Pratt & Whitney PT6-34AG engine and a Hartzell HC-B3TN-3C propeller; however, at the time of the accident, a PT6A-27 engine and Hartzell HC-B3TN-3D propeller with Blade Model T10282N+4 propeller blades were installed. The Hartzell propeller is a three-bladed constant speed, feathering and reverse capable propeller.

Review of the engine maintenance records revealed an entry dated March 20, 1992, indicating installation of the PT6A-27 engine. More recently, an entry dated April 2007, indicated a hot section inspection was performed. The engine total time at that time was recorded to be approximately 17,873 hours. The engine maintenance records also reflect an entry dated June 25, 2009, indicating removal, inspection, reassembly, and reinstallation of the power section. The engine total time at that time was recorded to be approximately 18, 379 hours.

The mechanic who performed the last power section inspection reported it was required due to propeller blade damage that occurred on landing by another pilot in Illinois in August 2008. The mechanic reported the following month he removed the propeller and power section of the engine but did not log the removal in the maintenance records. He completed the inspection and repair of the power section on February 1, 2009, and installed it on June 25, 2009. At that same time a new propeller was installed and an annual inspection was signed off as being completed. The airplane total time at the last annual inspection was reported to 11,614 hours, and the hour meter at that time was 3314.1 hours. The airplane was then flown by the chief pilot from Illinois, to North Carolina.

On June 29, 2009, approximately 5.0 hours since the new propeller was installed while the airplane was in North Carolina, the propeller was removed. Records indicated the bulkhead was removed and replaced, the propeller blade angles and track were checked, and the propeller was statically balanced. The propeller was re-installed with new hardware on July 6, 2009, and test run with no leaks noted. The mechanic who performed the work stated the propeller was removed in order to replace the propeller spinner dome. The airplane had been operated on two flights including the accident flight lasting a total of approximately 34 minutes since the propeller was last installed.

METEOROLOGICAL INFORMATION

A surface observation weather report taken at Elizabeth City Coast Guard Air Station/Regional Airport (ECG) at 1954, or approximately 27 minutes after the accident indicates the wind was from 070 degrees at 8 knots, the visibility was 10 statute miles, and clear skies existed. The temperature and dew point were 22 and 15 degrees Celsius, respectively, and the altimeter setting was 30.26 inches of Mercury. The ECG airport is located approximately 15 nautical miles and 094 degrees from the accident site location.

WRECKAGE AND IMPACT INFORMATION

Examination of the accident site by a FAA airworthiness inspector and also the operator revealed the airplane came to rest inverted in a corn field. Personnel of the operator and also the FAA reported damage to corn was only noted directly under the airplane. Damage to corn ahead of the right wing was attributed to fuel contact. The accident site was located at approximately 36.278732 degrees North latitude and 076.481743 degrees West longitude.

Examination of the airplane by several FAA airworthiness inspectors revealed no postcrash or in-flight fire. All components necessary to sustain flight remained attached. The left wing was more extensively damaged than the right wing. The leading edge of the left wing exhibited full-span chordwise crushing, and accordion wrinkles were noted on the left wingtip. Upward bulging of the lower skin of the left wing was noted while the airplane was inverted. The right wing exhibited compression wrinkles on the lower surface of the wing skin. The vertical stabilizer was crushed down. All primary and secondary flight controls remained attached; flight control continuity was confirmed for roll, pitch, and yaw. The flaps appeared retracted. The engine remained attached to the engine mount collar, but the engine was separated from the airframe. The propeller remained attached to the engine, but one propeller blade was separated from the propeller hub. The separated blade was located beneath the resting point of the engine.

Examination of the cockpit engine control quadrant revealed the propeller control was midrange, the fuel condition lever was in the "full forward" or flight idle position, and the power lever was in the "reverse" or full aft position. The FAA inspector reported the power lever gate tab was bent up approximately 90 degrees. Two global positioning system (GPS) receivers located in the wreckage were retained for further examination. The airplane was recovered and secured for further examination.

Examination of the engine following recovery by a representative of the engine manufacturer revealed impact damage to the lower section of the reduction gearbox and accessories attached to it including the propeller governor, propeller overspeed governor, and also Np tachometer generator. Examination of the exhaust duct revealed no evidence of blade contact marks on the interior surface. The gas generator case exhibite...