Incident Details
On January 10, 2014, during a scheduled 200-hour maintenance inspection on a Piaggio P180 Avanti I aircraft at the servicing station of Warsaw Chopin Airport (EPWA), technicians discovered cracks in the flanges of the exhaust collectors. A dye penetrant inspection confirmed the cracks, which exceeded allowable limits. The damaged collectors were removed and sent for repair. After repair, the collectors were reinstalled on the aircraft, which was subsequently returned to service.
Investigation Findings
The investigation, conducted by the aircraft operator under the supervision of Jacek Jaworski of the State Commission on Aircraft Accident Investigation (PKBWL), determined that the probable cause of the cracking was technical wear resulting from the specific operational profile of the aircraft. The aircraft had accumulated a high number of short engine cycles relative to its flight hours, a consequence of frequent engine shutdowns during medical missions. This pattern led to repeated heating and cooling of the collectors, often without complete cooling before the next engine start, subjecting the components to cyclic thermal stress.
Probable Cause
The probable cause of the incident was technical wear due to the specific operation of the aircraft, characterized by a large number of short engine cycles compared to total flight time.
Preventive Actions
The operator briefed operational and maintenance personnel on the incident, emphasizing the potential for damage and wear arising from the aircraft's operational patterns.