# NTSB ERA22LA104: Piper PA-32-300, N475RT, Edisto Island, SC, January 11, 2022 - Type: NTSB accident investigation - Classification: Accident · No injuries · Class 3 · Limited · Final report - Date: January 11, 2022, 12:47 local (17:47 UTC) - Place: Edisto Island, SC · field - Coordinates: 32.574029, -80.338475 (estimated) - Nearby events: https://openairdocs.org/map.md?lat=32.5740&lon=-80.3385&mi=10 - Phase of flight: [Enroute](https://openairdocs.org/ntsb-phases/400) (OpenAirDocs' grouping) - Defining event: [Enroute: Loss of engine power (total)](https://openairdocs.org/ntsb-events/341) - Highest injury: No injuries - Injuries: 1 uninjured - Status: Completed - Report: Approved by Office Director - Investigation class: Class 3 - NTSB office: Eastern Region Aviation - Parties: FAA/FSDO, Lycoming Engines - NTSB case key (mKey): 104516 - NTSB case page: https://web.ntsb.gov/investigations/?ntsbnumber=ERA22LA104 - NTSB report (PDF, downloads): https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/104516/pdf - NTSB docket: https://data.ntsb.gov/Docket?ProjectID=104516 - Page: https://openairdocs.org/ntsb/ERA22LA104 ## Probable cause A loss of engine power due to the fatigue failure of the crankshaft counterweight retaining ring and the No. 6 connecting rod. ## Findings NTSB's coded findings; those marked are part of the probable cause. - [Engine (reciprocating): recip eng cyl section](https://openairdocs.org/ntsb-findings/01058530): Aircraft › Aircraft power plant · Fatigue/wear/corrosion (probable cause); cases with it: [Piper PA-32-300, 6 cases](https://openairdocs.org/ntsb-findings/01058530/cases.md?model=7103212), [All aircraft, 373 cases](https://openairdocs.org/ntsb-findings/01058530/cases.md) - [Engine (reciprocating): recip engine power section](https://openairdocs.org/ntsb-findings/01058520): Aircraft › Aircraft power plant · Fatigue/wear/corrosion (probable cause); cases with it: [Piper PA-32-300, 3 cases](https://openairdocs.org/ntsb-findings/01058520/cases.md?model=7103212), [All aircraft, 233 cases](https://openairdocs.org/ntsb-findings/01058520/cases.md) ## Sequence of events The events NTSB coded, in order, by phase of flight. The defining event best describes what happened. - [Enroute: Loss of engine power (total)](https://openairdocs.org/ntsb-events/341) (defining event); cases with it: [Piper PA-32-300, 25 cases](https://openairdocs.org/ntsb-events/341/sequence.md?model=7103212), [All aircraft, 3,820 cases](https://openairdocs.org/ntsb-events/341/sequence.md) - [Emergency descent: Off-field or emergency landing](https://openairdocs.org/ntsb-events/440); cases with it: [Piper PA-32-300, 23 cases](https://openairdocs.org/ntsb-events/440/sequence.md?model=7103212), [All aircraft, 3,365 cases](https://openairdocs.org/ntsb-events/440/sequence.md) - [Landing-landing roll: Collision during takeoff/land](https://openairdocs.org/ntsb-events/490); cases with it: [Piper PA-32-300, 7 cases](https://openairdocs.org/ntsb-events/490/sequence.md?model=7103212), [All aircraft, 1,309 cases](https://openairdocs.org/ntsb-events/490/sequence.md) ## Analysis Shortly after takeoff the engine started to “sputter,” then stopped producing power; oil then blew out of the engine cowling onto the windshield. The pilot made a forced landing in a field and the airplane contacted a wire fence, resulting in substantial damage to the airframe. A postaccident inspection of the engine revealed that the engine crankcase was ruptured in two places near the Nos. 5 and 6 cylinders. Subsequent detailed examinations showed the Nos. 5 and 6 connecting rods were fractured and that a counterweight retaining ring (circlip) was missing its eyelets and had separated from the counterweight assembly. Additional metallurgical examination revealed that the counterweight retaining ring failed due to fatigue. The failure allowed the counterweight roller to eject from the counterweight. Additionally, the No. 6 connecting rod exhibited evidence of a fatigue failure in multiple locations and the Nos. 5 and 6 pistons showed evidence of detonation. It is likely that the fatigue failure of the retaining ring or the fatigue failure of the No. 6 connecting rod occurred and propagated throughout the engine until a catastrophic failure resulted. The failure sequence could not be determined, but it is likely that the piston detonation exacerbated the process. ## Factual narrative On January 11, 2022, about 1247 eastern standard time (EST), a Piper, PA-32-300, N475RT, was substantially damaged when it was involved in an accident near Edisto Island, South Carolina. The private pilot was not injured. The airplane was operated as a Title 14 Code of Federal Regulations Part 91 personal flight. According to the pilot, who was also the owner of the airplane, the first leg of the flight was uneventful. After landing at Columbus County Municipal Airport (CPC), Whiteville, North Carolina to get fuel, he resumed the flight to Florida. After departure, about 15 minutes into the flight, while cruising at 4,500 ft mean sea level, the engine started to sputter, then stopped, followed immediately by oil coming out of the engine cowling onto the windshield, partially limiting his field of view. Seeing no immediate landing location ahead of him, the pilot maintained 100 mph, turned 180° and declared an emergency. The pilot observed a straight road between two fields out of his side window and proceeded towards the area. After setting up for a short final to the road, he observed an electrified livestock fence on both sides of the road, but he was already committed for landing and was unable to avoid the fence. After touching down, both wings struck the fence. The airplane veered to the right traveled through the fence, and into a field for about 300 ft before coming to rest. The airplane came to rest upright. The right wing contained a large tear in the leading edge and the right landing gear collapsed. Closer examination of the engine revealed oil spray and a hole located on top of the No. 6 cylinder. The airplane was transported to a secured facility and the engine, and its components were subsequently examined. One propeller blade was twisted with its blade tip torn off. The other blade was bent aft about mid span. The propeller governor remained attached to the engine. The propeller governor gasket was found free of debris. All other components were free of preimpact or anomalous damage. All the spark plugs appeared slightly dark in color but were otherwise considered normal wear in accordance with the Champion Aviation Check-A-Plug chart. Two holes were found at the rear of the engine above the Nos. 5 and 6 connecting rods, exposing the camshaft. Crankshaft continuity could not be established because of internal damage that prevented movement. Upon disassembly, the Nos. 5 and 6 connecting rods were found broken at the connecting rod caps with no heat signatures present. One connecting rod cap bolt remained intact (bent) with visible threads and a missing nut. Both connecting rod caps were broken into pieces. Minor scoring was noted on the adjacent bearings and surfaces. The engine oil pump also showed minor scoring on the pump housing and there was ferrous material located in the pleats of the oil filter. The Nos. 5 and 6 piston crowns and cylinder head domes exhibited features consistent with detonation. The piston crowns weresmooth and clean and had the appearance of being sandblasted with the compression and oil rings compressed into the ring walls. The internal retaining ring (circlip), washer, and roller were found separated from one of the counterweights. All of the internal retaining rings exhibited anomalous damage; their eyelets were broken off. One of the counterweight circlips had features consistent with fatigue and subsequent failure. The failed circlip corresponded to a counterweight roller that was ejected from the counterweight assembly. In addition, the No. 6 connecting rod showed evidence of fatigue failure in multiple areas. The areas showing fatigue were located on the main body of the rod and on the cap, along the bearing surfaces in the area where the connecting rod bolt joined them together, and where the I-beam of the rod transitioned to the bearing end of the rod. In addition, the Nos. 5 and 6 piston crowns, valve faces, and cylinder head domes were clean and free of combustion residue. The engine had accrued about 555 hours since overhaul by the manufacturer in 2011. ## Aircraft - Registration: [N475RT](https://openairdocs.org/deregistered/N475RT-2024-07-06), registration cancelled 2024-07-06, S/N 32-7540028, built 1974 (OpenAirDocs) - Reported make and model: PIPER PA-32-300 - Registry model: [Piper PA-32-300](https://openairdocs.org/model/piper-pa-32-300) (registry code 7103212) (OpenAirDocs) - Registry engine: [Lycoming TI0-540 series](https://openairdocs.org/engine/lycoming-ti0-540-series) (registry code 41533, turbo-prop) (OpenAirDocs) - Category: Airplane - Serial number: 32-7540028 - Year built: 1974 - Airframe hours: 3191 - Engines: Lycoming IO-540-K1A5 300 horsepower reciprocating - Damage: Substantial damage - Flight: Personal, Part 91 - Airworthiness certificate: Standard, Normal - Last inspection: Annual, March 1, 2021 - Departed: CPC, Whiteville, NC - Destination: SUA, Stuart, FL - Equipment: ADS-B, Auto-pilot, Electronic primary flight display, Onboard weather ## Flight crew As NTSB recorded them. NTSB leaves out names. - Pilot; age 66; injuries: none; private; airplane ratings: single-engine land; medical: class 3, with waivers/limitations; last flight review April 25, 2020; seat: left; restraint: 3-point; flight hours: 386.6 total, 260.7 in this make and model, 309 as pilot in command, 22.4 in the last 90 days, 19.5 in the last 30 days, 6.7 in the last 24 hours ## Weather - Conditions: Visual (VMC), Day - Wind: 50° at 4 knots - Visibility: 10 statute miles - Lowest ceiling: none - Temperature: 50 °F, dew point 16 °F - Altimeter: 30.48 inHg - Observed at: JZI, 19 nm away - METAR: KJZI 111815Z AUTO 05004KT 10SM CLR 10/M09 A3048 RMK AO2 ## FAA reports on this event (1) The FAA's own accident and incident reports, matched to the aircraft by N-number and date (OpenAirDocs). - [Accident 20220111000489A](https://openairdocs.org/incident/20220111000489A), Jan 11, 2022: Piper PA-32-300, Edisto Island, SC, Substantial damage. On January 11, 2022 approximately at 1247 eastern standard time a Piper PA-32-300 experienced a loss of power on a cross country flight and the pilot in… ## Docket (9 files) The files NTSB released with the investigation on October 5, 2023, on NTSB's docket system: https://data.ntsb.gov/Docket?ProjectID=104516. 252 MB in all. - Pilot/operator aircraft accident report, NTSB form 6120.1 (item 1, PDF, 9 pages, 25.7 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=15072132&FileExtension=pdf&FileName=Pilots%206120.1%20Accident%20Report_Redacted-Rel.pdf - Pilot statement (item 2, PDF, 1 page, 115 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=15962189&FileExtension=pdf&FileName=Pilot%27s%20E-mail%20Report%20to%20FAA_Redacted-Rel.pdf - Engine maintenance records_excerpt (item 3, PDF, 7 pages, 209 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=15962779&FileExtension=pdf&FileName=Maintenance%20Records%20Excerpt_Engine_Redacted-Rel.pdf - NTSB airframe and engine examination report (item 4, PDF, 7 pages, 690 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16160970&FileExtension=pdf&FileName=ERA22LA104%20Airframe%20and%20Engine%20Exam_NTSB-Rel.pdf - Lycoming engines materials lab report _redacted (item 5, PDF, 36 pages, 13.1 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16159630&FileExtension=pdf&FileName=N475RT%20Lycoming%20Engines%20Report%20(Broken%20connecting%20rods)_Redacted1_Redacted-Rel.pdf - Memorandum for record - permission from Lycoming engines to release materials laboratory investigation report (item 6, PDF, 1 page, 161 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16160693&FileExtension=pdf&FileName=MOR_Lycoming%20Approval%20to%20use%20Examination%20Report%20in%20Public%20Docket_Redacted-Rel.pdf - Photo array_accident site and airplane damage (item 7, PDF, 5 pages, 1.1 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=15962052&FileExtension=pdf&FileName=Photo%20Array_Accident%20Site%20and%20Damage-Rel.pdf - Photo array_initial engine examination (item 8, PDF, 7 pages, 1.3 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=15962823&FileExtension=pdf&FileName=Photo%20Array_Initial%20Examination%20of%20Engine-Rel.pdf - Lycoming party form_signed (item 9, PDF, 10 pages, 468 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=15962231&FileExtension=pdf&FileName=Party%20Form%20-Edisto%20Island_Redacted-Rel.pdf From the NTSB's public API. Aircraft are matched to registry aircraft by N-number and event date, checked against the reported serial number, make and model; the registry's history has gaps, so older matches can be wrong. Compare the reported make and model. --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain.