2000
St. John’s Newfoundland-based offshore oil industry carrier Cougar Helicopters are among the first carriers in the world to sign up to purchase the new Sikorsky S92 helicopter.

2002
August
"Sikorsky S92’s first loss of lubrication test was conducted with a simulated catastrophic loss of lubrication. With this loss of lubrication failure mode and resulting oil depletion rate, indication of imminent gearbox failure was observed approximately 10 minutes into the test and the test was discontinued at that point. Observations upon disassembly confirmed that the failure was imminent (FAA statement to the fifth estate)."

This test was done to comply with Federal Aviation Regulation 29.927 (c) (1) Category A. which states that “Unless such failures are extremely remote, it must be shown by test that any failure which results in loss of lubricant in any normal use lubrication system will not prevent continued safe operation, although not necessarily without damage, at a torque and rotational speed prescribed by the applicant for continued flight, for at least 30 minutes after perception by the flightcrew of the lubrication system failure or loss of lubricant.”

November
A second test with the by-pass system in place was conducted on Nov. 16, 2002. This test supported the ultimate compliance finding to 29.927(c).

"At the time of the certification review for the S92, FAA guidance material for compliance to 14 CFR Part 29.927(c) highlighted that the most likely area for major lubrication loss would be from external lines and systems generally associated with a gearbox lubrication cooling system. With this guidance, the primary focus and concern for this requirement was with an external failure and resulting lubrication fluid loss in any external system. As FAA guidance material is generated from service experience with other rotorcraft across the industry and with recognized best practices, this was considered the appropriate area for FAA focus and oversight. In general, Sikorsky products, both civil and military models, have not had a recognized adverse service history with gearbox mounted lubrication filtering sub-systems. This further supported the compliance focus in the external systems area (FAA statement to the fifth estate)."

December
Sikorsky S92 helicopter is certified by the Federal Aviation Administration. It is Sikorsky’s first civilian helicopter to be certified in over two decades. The S92 is the first helicopter in the world to be certified to Federal Aviation Regulation Part 29 Transport Rotorcraft, Amendment 47, the latest U.S. safety regulations.

FAA administrator Amy Corbett calls the S92 “the world’s safest helicopter.”

2003
The Washington based National Aeronautical Association awards the S92 the Robert J. Collier Trophy for “the greatest achievement in aeronautics or astronautics in America, with respect to improving the performance, efficiency and safety of air or space vehicles, the value of which has been thoroughly demonstrated by actual use during the preceding year.”

2004
The S92 is certified in Europe by the European Aviation Safety Agency/Joint Aviation Authorities

Ottawa inks a $5 billion dollar deal for 28 new marine helicopters to replace the Canadian military’s aging Sea King fleet. The Canadian military choose the Sikorsky H-92 (later dubbed the CH-148 Cyclone) -- a military variant of Sikorsky’s new state-of-the-art S92 helicopter.

2005
February
S92 is certified by Transport Canada

St John’s Newfoundland-based Cougar Helicopters first S92 goes into service.

Helicopter pilot Matthew Davis begins his new job with Cougar.

June
After a reported loss of oil pressure in the main gearbox of an S92 operating in the North Sea, the FAA issues an airworthiness directive requiring “replacing the main gearbox (MGB) lubrication/scavenge pump vespel spleen adapters before further flight, and thereafter, replacing them at certain intervals…The actions specified in this AD are intended to prevent loss of lubrication to the MGB, which could cause failure of one or both engine input drives, or planetary gear to sun gear tooth mesh failure, resulting in loss of power to the rotor system and subsequent loss of control of the helicopter.” Read FAA Document

2006
August
The FAA issues an airworthiness directive for the S92 requiring “before further flight, replacing a certain main gearbox (MGB) upper main housing assembly that has 2700 or more hours time-in-service (TIS) with an airworthy part. This action also requires, before further flight, revising the Airworthiness Limitations section of the maintenance manual by establishing a new retirement life for the MGB housing assembly of 2700 hours TIS. This amendment is prompted by testing of the MGB housing assembly that resulted in premature fatigue due to a manufacturing process creating an oxide skin defect in the housing. The actions specified in this AD are intended to prevent fatigue failure of the MGB housing, loss of MGB lube oil, loss of main and tail rotor drive, and subsequent loss of control of the helicopter.” Read document

2008
January
Discussion circulates on the web that an S92 made an unscheduled landing in Malaysia after oil leak in the main gearbox.

July 2
Vancouver-based CHC Helicopters-owned Sikorsky S92 carrying 14 passengers and two crew enroute from offshore oil rig makes emergency landing near Broome, Australia after two studs securing the oil filter assembly to the main gearbox break and cause massive oil loss. Read Occurrence Report

July 14
The FAA Boston Certification office contact Australian Civil Aviation Authority to request the failed studs be sent to Sikorsky for analysis at their laboratory.

July 22
Amdel metallurgical lab in Australia examines failed studs on Broome S92 main gearbox.

“…The preliminary conclusion is that the stud fractures are most likely overload, probably from overtightening…”

July 23
Email from Transportation Safety Board of Canada’s Bill Yearwood to Australian Civil Aviation Safety Authority and CHC Helicopters regarding TSB oversight of examination of failed studs from Broome S92 in Canada. Read email

August 26/27
The failed studs from the downed S92 near Broome are examined by R.J. Waldron & Co of Richmond, B.C. under the supervision of Travis Shelongosky (TSB Canada). Representatives from CHC Helicopters and Sikorsky attend the examination.

August 29
Transportation safety Board of Canada’s Bill Yearwood emails FAA after examination at Waldron labs, attached is summary of the findings written by TSB’s Travis Shelongosky. Read Yearwood email; Read TSB Summary

August 29
FAA acknowledge receiving email and summary from Transportation Safety Board of Canada’s Bill Yearwood. Read email

September 3
CHC Helicopters email Transportation Safety Board of Canada and R.J. Waldron & Company thanking them for the oversight and examination. Read email.

September 25
R.J. Waldron & Company of Richmond B.C. produce report on failed studs on Broome S92.
Read report.

September 26
Sikorsky publishes Safety Advisory regarding flight manual changes prompted by problems with MGB lubrication system in the S92.

2009
January 28
Sikorsky issues Alert Service Bulletin indicating that the main gearbox oil filter bowl assembly mounting titanium studs on the S92 should be replaced with steel mounting studs. This modification is to be accomplished within the next 1250 flight hours or within one year of the issue date of the ASB, whichever occurs first.

March 12
Cougar S92 Flight 491 enroute to Hibernia and Sea Rose platforms in the Grand Banks crashes into the ocean killing two crew and 15 passengers. One passenger, Robert Decker, survives.

March 20
Sikorsky releases Alert Service Bulletin 92-63-014A (revising their January 28 ASB) now requiring replacement of titanium MGB oil filter mounting studs with steel studs before further flight. Read the Sikorsky Alert Service Bulletin

March 20
Transportation Safety Board of Canada publicly discloses that it found a broken main gearbox oil filter bowl assembly mounting stud in wreckage of Flight 491. View the TSB Flight 491 investigation webpage.

March 23
FAA issues Emergency Airworthiness Directive requiring immediate replacement of main gearbox oil filter bowl assembly studs on all Sikorsky S92s before further flight. Read the FAA Emergency Airworthiness Directive.

April 8
Canada-Newfoundland and Labrador Offshore Petroleum Board (C-NLOPB) announces Inquiry into offshore worker safety in wake of Flight 491 crash. View the Offshore Helicopter Safety Inquiry webpage.

June 11
Families of deceased Flight 491 passengers and lone survivor Robert Decker file a law suit against Sikorsky and two other companies in Pennsylvania. The matter is settled out of court months later.

June 18
Transportation Safety Board of Canada issues update into their crash investigation of Flight 491.
View the TSB 491 investigation webpage.

July 1
FAA issues amendment to March AD requiring changes to the S92 flight manual because “certain MGB Normal and Emergency procedures in the RFM are unclear, may cause confusion and may mislead the crew regarding MGB malfunctions, in particular the urgency to land immediately after warning indications of loss of MGB oil pressure and oil pressure below 5 pounds per square inch (psi)…” View the FAA Airworthiness Directive

October 19
Offshore Helicopter Safety Inquiry hearings begin in St John’s

October 23
European Aviation Safety Agency issues Emergency Airworthiness Directive re cracking found in S92 MGB assembly mounts. Read the European Aviation Safety Agency issues Emergency Airworthiness Directive.

November 5
Lone survivor of Cougar Flight 491 crash, Robert Decker, testifies at Offshore Helicopter Safety Inquiry in St John’s. Read Robert Decker's full testimony at the Offshore Helicopter Safety Inquiry webpage (starts on page 3).

December 21
FAA issues Airworthiness Directive requiring inspection of S92 main gearbox oil filter and assembly. Read the FAA Airworthiness Directive