BERRY AVIATION INC

Operated by Berry Aviation, Inc. (per NTSB report)

Operated by Berry Aviation (per NTSB report)

HYDRAULIC PUMP CIRCUIT BREAKER POPPED IN FLIGHT AND MAIN SYSTEM WOULD NOT HOLD PRESSURE. CREW DECLARED AN EMERGENCY AND SAFELY LANDED AT KHYI. MAINTENANCE FOUND HYDRAULIC MANIFOLD CAP TOO BE LOOSE AS WELL AS A LEAK ON INLET, ON FILTER HOUSING AND SUBSEQUENTLY SECURED THE MANIFOLD CAP AS WELL AS REPLACING THE PACKINGS, O-RINGS, AND FILTER. LEAK/OP CHECK WAS PERFORMED AND FOUND SATISFACTORY.

WHILE AT 28K ALTITUDE, CREW TURNED PACKS ON HIGH (HEAT), AFTER 20MIN RT PACK FAILED INDICATION ILLUMINATED, CREW FOLLOWED QRH. ABOUT A MIN LATER WITH PACKS ON LOW SETTING, CREW STARTED GETTING SMOKE. CREW FOLLOWED QRH FOR SMOKE BUT SMOKE DIDN’T EVAC FAST ENOUGH. CREW DESCENDED TO 10K & EMERGENCY DECLARED BY ATC. BY THE TIME 10K WAS REACHED, SMOKE WAS CLEAR. WHILE ON APPROACH TO KMQY CREW RAN THE PACKS IN LOW & NORMAL WITHOUT INCIDENT. SMOKE WAS MINIMIZED BY SHUTTING OFF PACKS, RECIRC FANS, AND GASPER FANS. SMELL WAS DESCRIBED AS SIMILAR TO WHEN A HOUSES HEATER IS USED FOR THE FIRST TIME. PERFORMED OPS CHECK OF BOTH PACKS IAW MM 21-60-00, NO DISCREPANCIES NOTED. PERFORMED VISUAL INSPECTION OF BOTH PACKS WITH NO DISCREPANCIES NOTED. CONTINUED OPS IAW MEL 21-50-2.

LOSS OF GREEN HYDRAULIC SYSTEM PRESSURE, RESULTING IN EMERGENCY PROCEDURES. EMERGENCY DECLARED AND GEAR WERE EXTENDED AND LOCKED. SMOKE APPEARED IN COCKPIT OF GEAR WAS DOWN AND LOCKED. INSPECTED AIRCRAFT AN FOUND ENGINE DRIVEN PUMP PRESSURE LINE ELBOW FITTING WITH EXCESSIVE CHAFFING, CAUSING A LEAK AND LOSS OF HYDRAULIC FLUID. REMOVED AND REPLACED FITTING AND SERVICED HYDRAULIC SYSTEMS. OPS CHECK NORMAL. INSPECTED AIRCRAFT ENGINE AND DETERMINED THAT THE SMOKE WAS GENERATED FROM THE HYDRAULIC FLUID LEAK BEING INGESTED INTO THE ENGINE INTAKE AND SUBSEQUENTLY INTO THE AIRCRAFT BLEEDS.

DURING FLIGHT THE FLIGHT CREW TURNED ON THE CABIN/COCKPIT HEAT. THE CREW HAD SMOKE IN THE COCKPIT. THE CREW THEN SELECTED THE TEMP CONTROLLER TO COLD AND TURNED THE HEAT OFF. THE SMOKE IN THE COCKPIT CLEARED OUT. TROUBLESHOOTING IS CURRENTLY IN WORK.

RH ENGINE SHOWED SIGNS OF COMPRESSOR STALL ON TAKEOFF. AFTER DEPARTURE POWER WAS PULLED BACK ON THE RH ENGINE, THE ENGINE AUTOFEATHERED. TROUBLESHOOTING IS CURRENTLY IN WORK IAW THE FIM.

TROUBLESHOOTING OF THE RH ENGINE STALL DETERMINED THAT THE E2 ANTI ICE/START VALVE WAS STICKING. REMOVED AND REPLACED THE VALVE. ADDITIONAL TROUBLESHOOTING FOUND LEAKING BLEED LINES AT THE HP AND LP VALVES. REMOVED AND REPLACED CLAMPS. PERFORMED RECOVERY COMPRESSOR WASH. PERFORMED POWER RUNS WITH NO DEFECTS NOTED.

THE AIRCRAFT EXPERIENCED A COMPLETE ELECTRICAL POWER LOSS DURING CRUISE. THE LH GENERATOR WAS ON MEL. TROUBLESHOOTING DETERMINED THAT THE RH GENERATOR HAD FAILED. BOTH THE LH AND RH GENERATOR WERE REPLACED.

DURING TAKEOFF, LH ENG T6 OVER HEAT, ENGINE WAS SHUT DOWN AS A PRECAUTION. SMOKE WAS PRESENT IN THE COCKPIT. UPON WALKAROUND OIL WAS PRESENT ON THE EXTERIOR OF ENGINE COWING. MAINTENANCE PERFORMED A BORESCOPE AND IDENTIFIED OIL IN THE COMBUSTION CHAMBER WITH POSSIBLE #6 BEARING DETERIORATION BEING THE CAUSE. ENGINE WAS REPLACED.

WHILE ACCOMPLISHING A REPAIR OF THE IB SIDE SKIN OF THE RH ENGINE NACELLE, AFTER REMOVAL OF THE EXISTING STRINGER [PN 120-41441-002] THE FWD. SPLICE-PROFILE 1 [PN 120-18760-009] WAS FOUND TO BE CRACKED/BROKEN. PART IS TO BE REPLACED WITH NEW PART.

DURING THE HEAVY CHECK MAINTENANCE VISIT CORROSION WAS FOUND UNDER THE RIGHT HAND STRAKE AT THE AFT FUSELAGE SECTION BETWEEN FS 17088 TO 17103.64 AT STRINGERS 16R A PERMANENT REPAIR WAS INSTALLED IAW EMB120 ETD2022-120-029431 REV A.

LEFT HAND ENGINE NACELLE, IB SIDE , UPPER FWD SUPPORT ROD FWD CLEVIS WAS FOUND TO BE SHEARED AT THE THREADED PORTION OF THE CLEVIS

LEFT HAND ENGINE NACELLE, IB SIDE, UPPER FWD SUPPORT ROD CLEVIS WAS FOUND TO BE SHEARED AT THE THREADED PORTION OF THE CLEVIS.

DURING PREFLIGHT INSPECTION, IT WAS FOUND THAT THE RH NACELLE HYDRAULIC DOOR HAD DEPARTED THE AIRCRAFT DURING THE LAST FLIGHT. THE DOOR HAD DAMAGED THE INBD FLAP. INSPECTED AIRCRAFT FOR FURTHER DAMAGE. REMOVED AND REPLACED THE RH INBD FLAP. REPAIRED RH NACELLE HYD DOOR HINGE AREA AND INSTALLED NEW DOOR ASSEMBLY.

BIRD STRIKE ON THE UPPER FUSELAGE, CAUSING DAMAGE TO THE CROWN ABOVE AND AFT OF THE COCKPIT WINDOWS AND FWD VHF 1 ANTENNA, DAMAGE TO ANTENNA MOUNT POINT BETWEEN STA 6249.2. AND STA 6462.6 BETWEEN STRINGER 1L AND 1R, FRAMES 19A AND 20. ADDITIONAL FUSELAGE DAMAGE ABOVE AND TO THE LEFT OF THE COCKPIT WINDOWS, 3 DENTS LOCATED BETWEEN FRAMES 10 AND 13, STRINGERS 1L & 5L, BETWEEN STA 3293.0 AND 4068.0

BLEED SYSTEM PRSOV SPACE MOUNTING EARS FOUND CRACKED. REMOVED SPACER, REPLACED CRACKED ANGLES P/N 85531139-101 & 85531139-105. RE-INSTALLED REPAIRED SPACER.

BLEED SYSTEM PRSOV SPACE MOUNTING EARS FOUND CRACKED. REMOVED SPACER, REPLACED CRACKED ANGLES P/N 85531139-101 & 85531139-105. RE-INSTALLED REPAIRED SPACER.

BLEED SYSTEM PRSOV SPACE MOUNTING EARS FOUND CRACKED. REMOVED SPACER, REPLACED CRACKED ANGLES P/N 85531139-101 & 85531139-105. RE-INSTALLED REPAIRED SPACER.

BLEED SYSTEM PRSOV SPACE MOUNTING EARS FOUND CRACKED DURING ROUTINE MAINTENANCE. REMOVED AND REPLACED SPACER ASSEMBLY.

EMPTY LEG REPOSITION FLIGHT FROM KYIP TO KCAK. CLIMBING THROUGH 14,000' AFTER DEPARTING KYIP THE EMERGENCY DC BUS #2 FAILED. EMERGENCY WAS DECLARED WITH ATC AND CREW REQUESTED DIVERSION BACK TO KYIP. LANDING GEAR COLLAPSED UPON LANDING AND AIRCRAFT EXITED THE RUNWAY. INVESTIGATION IS UNDERWAY WITH MORE DETAILS TO COME.

DURING SCHEDULED MAINTENANCE A FUEL LEAK WAS NOTED AT ACCESS PANEL 622EB. MAINTENANCE PERSONNEL EVALUATED THE LEAK AND DETERMINED ITS SOURCE TO BE FROM A RIVET IN STRINGER 10 AT WING STATION Y-2343. AFTER REMOVING THE RIVET AND CLEANING THE AREA STRINGER 10 WAS FOUND CRACKED. THE CRACKED AREA WAS CUT OUT AND THE STRINGER WAS SPLICED IN ACCORDANCE WITH EMBRAER SRM 57-20-03. NDT WAS PERFORMED TO VERIFY NO OTHER CRACKS IN THE AREA AND THE AIRCRAFT WAS RETURNED BACK TO SERVICE.

SHORTLY AFTER TAKEOFF FROM KACK THE CREW NOTICED WHAT SEEMED TO BE SMOKE OR FOG COMING FROM BEHIND THE GLARESHIED ON THE CAPTAINS SIDE. THE CREW DONNED THEIR OXYGEN MASKS, DECLARED AN EMERGENCY, AND RETURNED BACK TO KCAK AND LANDED WITHOUT FURTHER ISSUE. KCAK BASED MAINTENANCE FOUND DE-ICING FLUID IN THE INTAKE OF THE APU WHICH UPON ROTATION MADE ITS WAY INTO THE BLEED AIR DUCTS CAUSING THE SMOKE. MAINTENANCE CLEANED ALL DE-ICING FLUID FROM THE APU INLET AND PERFORMED AN OPERATIONAL CHECK OF THE APU BLEEDS, WITHOUT ANY DEFECTS NOTED. MAINTENANCE ALSO INSPECTED ALL ELECTRICAL COMPARTMENTS IN THE COCKPIT FOR ANY BURNT WIRES OR COMPONENTS, WITH NO DEFECTS NOTED. A MAINTENANCE TEST FLIGHT WAS THEN PERFORMED TO VERIFY THE FIX, WITH NO DEFECTS NOTED. THE AIRCRAFT WAS THEN RETURNED TO SERVICE.

NUMBER 2 ENGINE FLAMED OUT DURING CRUISE FLIGHT. AFTER LANDING MAINTENANCE FOUND THE NUMBER 8 FUEL NOZZLE LEAKING FROM THE TRANSFER TUBES, DUE TO AN INCORRECTLY INSTALLED LOCKING PLATE. MAINTENANCE THEN REMOVED THE LOCKING PLATE AND TRANSFER TUBES, REPLACED THE TRANSFER TUBES O-RINGS, AND REINSTALLED TRANSFER TUBES AND LOCKING PLATE IN THE CORRECT POSITION IN ACCORDANCE WITH THE PRATT AND WHITNEY CANADA ENGINE MAINTENANCE MANUAL CHAPTER 73-10-05. MAINTENANCE THEN PERFORMED ALL NECESSARY GROUND RUNS AND LEAK CHECKS WITH NO DEFECTS NOTED.

PILOT SMELLED SMOKE IN THE COCKPIT AND POSSIBLE FIRE NEAR RH PACK. EMERGENCY DECLARED AND AIRCRAFT LANDING SAFELY. PERFORMED VISUAL INSPECTION OF LH & RH PACK BAYS FOR PACK UNIT OVERHEATING. NO DEFECTS NOTED. INSPECTED AREA OF PACK DUCT PENETRATION INTO CABIN UNDER FLOORBOARDS WITH NO DEFECTS NOTED. PERFORMED OPERATIONAL CHECK OF PACK SYSTEM, LH & RH SIDE, IN LOW, NORMAL AND HIGH UTILIZING ENGINE & APU BLEEDS . NORMAL OPERATION NOTED. AIRCRAFT RETURNED TO SERVICE. PILOT REPORTED THAT RH PACK HAD BEEN INADVERTENTLY POSITION TO THE HIGH SETTING

A MAINTENANCE TEST FLIGHT FOR NACELLE FLAP DISAGREEMENT WAS IN PROGRESS. DURING THE TEST FLIGHT THE CREW WAS IN CRUISE CONFIGURATION AND INCREMENTALLY SET THE FLAPS UNTIL THEY WERE FULLY DOWN. UPON MOVING THE FLAPS BACK TO 25 DEGREES THEY EXPERIENCED A FLAP DISAGREEMENT BETWEEN THE NACELLE FLAPS. IN TRYING TO CORRECT THE ISSUE THE ALSO EXPERIENCED A FLAP ASYMMETRY IN THE NACELLE FLAPS. AT THIS POINT IT WAS DECIDED TO HEAD DIRECT TO KHYI FOR AN EMERGENCY LANDING. UPON ARRIVAL AT KHYI MAINTENANCE TROUBLESHOT THE FLAP ISSUE TO A FAULTY CANNON PLUG AT THE RH NACELLE FLAP ACTUATOR. MAINTENANCE REMOVED AND REPLACED THE CANNON PLUG AND PERFORM OPS CHECKS WITH NO DEFECTS NOTED. THE AIRCRAFT THEN PERFORMED ANOTHER MAINTENANCE TEST FLIGHT WITH NO FURTHER DEFECTS NOTED.

THE CREW EXPERIENCED AN INTERMITTENT FIRE INDICATION WARNING LIGHT FOR THE NUMBER 2 ENGINE WHILE ON SHORT FINAL. THE CREW LANDED THE AIRCRAFT AND REPORTED THE ISSUE TO ON-SITE MAINTENANCE PERSONNEL. MAINTENANCE TROUBLESHOT THE ISSUE TO A FAULTY FIRE CONTROL PANEL. THE FIRE CONTROL PANEL WAS REMOVED AND REPLACED AND OPERATIONAL CHECKS WERE PERFORMED SATISFACTORY AND THE AIRCRAFT WAS RETURNED TO SERVICE.

RH ATTITUDE INDICATOR SCREEN WENT BLANK, THEN CREW NOTED SMOKE ODOR IN COCKPIT. EMERGENCY DECLARED AND AIRCRAFT DIVERTED TO THE NEAREST AIRPORT. REMOVED AND REPLACED RH EADI. OPS CHECK GOOD.

RH SEAT TRACK BETWEEN FRAMES 14-15 HAS CORROSION. INSTALLED NEW SEAT TRACK (REF EMB120 AMM 53-01-05 REV 44).

APU COWL RH UPPER MOUNT FITTING, LOWER SUPPORT STRUCTURE IS CRACKED. INSTALLED NEW SUPPORT STRUCTURE (REF EMB120 SRM 51-25-00 REV 58)

LH WING INTERNAL RIB 19 FWD MOST UPPER SKIN TO RIB SHEAR CLIP IS CRACKED. INSTALLED NEW SHEAR CLIP (REF EMB120 SRM 51-40-02 REV 58)

LH WING INTERNAL RIB 19, 3RD UPPER SKIN TO RIB SHEAR CLIP FROM FRONT SPAR IS CRACKED. INSTALLED NEW SHEAR CLIP (REF EMB120 SRM 51-40-02 REV 58).

LH WING INTERNAL RIB 19 AFT MOST UPPER SKIN TO RIB SHEAR CLIP IS CRACKED. INSTALLED NEW SHEAR TIE (REF EMB120 SRM 51-40-02 REV 58)

LH LOWER WING STRINGER FWD OF 551BB AT RIB 16 IS CRACKED. REPAIRED AND INSTALLED STRINGER (IAW EMB120 SRM 58-20-03 FIG 202, EMBRAER ETD 019-120-121013)

LH WING RIB 16 2ND FROM THE AFT SHEAR TIE IS CRACKED. INSTALLED NEW SHEAR TIE (REF EMB120 SRM 51-40-02 REV 58)

LH WING RIB 15 2ND FROM THE AFT SHEAR TIE IS CRACKED. INSTALLED NEW SHEAR TIE (REF EMB120 SRM 51-40-02 REV 58).

LH WING RIB 15 2ND FROM THE FWD SHEAR TIE IS CRACKED. INSTALLED NEW SHEAR TIE (REF EMB120 SRM 51-40-02 REV 58)

FOUND CRACKED SHEAR TIE WHILE INSTALLING DOUBLER AT LH WING FUEL TANK RIB 21 FWD OF THE AFT STIFFENER. INSTALLED NEW SHEAR TIE (REF EMB120 SRM 51-40-02 REV 58)

RH WING UPPER SURFACE SKIN BETWEEN RIBS 22-23 HAS CORROSION AT MIDDLE VORTEX GENERATOR INSTALLED REPAIR (PER EMB ETD 2019-120-129256)

LH WING #10 STRINGER CRACKED AT STATION YA-1359. REPAIRED STRINGER IAW 57-20-03

RH WING #10 STRINGER CRACKED AT STATION YA-2593.REPAIRED STRINGER IAW 57-20-03

RH NACELLE FLAP INTERNAL TRAINING EDGE STUB RIB AFT OF LOWER SKIN ACCESS HOLE IS CRACKED & HAS ENLARGED FASTENER HOLES. MATCHDRILLED NEW STUB RIB (REF EMB120 SRM 51-25-00 REV 58). INSTALLED NEW STUB RIB (REF EMB120 SRM 51-40-02 REV 58).

RH NACELLE FLAP TRAILING EDGE LOWER SKIN ATTACH FLANGE IS CRACKED. LOCATED AND DRILLED NEW RH NACELLE FLAP TRAIILING EDGE LOWER SKIN ATTACH FLANGE (IAW EMB120 SRM 51-40-04 REV 58). INSTALLED ATTACH FLANGE (IAW EMB120 SRM 51-40-02 REV 58).

INTERCOSTAL BETWEEN FRAMES 39-40, STRINGER 3R IS CRACKED. LOCATED AND DRILLED NEW INTERCOSTAL (IAW EMB120 SRM 51-40-04 REV 58). INSTALLED INTERCOSTAL AND SUPPORT BRACKET BETWEEN FRAMES 39-40 STR3R (IAW EMB120 SRM 51-40-02 REV 58).

LH WING UPPER SKIN HAS CORROSION AFT OF THE VORTEX GENERATOR AT RIB 21. FABRICATED REPAIR DOUBLER AND FILLER PIECE FROM 2024-T3 .080" (PER ETD 2019-120-101457). INSTALLED DOUBLER AND VORTEX GENERATOR (PER 2019-120-101457). APPLIED CAP SEAL TO FASTENERS WITHIN FUEL TANK CORROSION TO REPAIR DOUBLER (PER EMB ETD 2019-120-101457 AND EMB120 SRM 51-22-00 REV 58).

LH WING LEADING EDGE ATTACH ANGLE RIB AT INBOARD SIDE OF NACELLE IS CHAFED IN MULTIPLE AREAS. MATCHDRILLED NEW LEADING EDGE ATTACH (REF EMB120 SRM 51-25-00 REV 58). INSTALLED NEW LEADING EDGE ATTACH (REF EMB120 SRM 51-40-02 REV 58). APPLIED SURFACE PROTECTION (REF EMB120 CPM 51-21-04 REV 10, CPM 51-21-05 REV 10, AND COM 51-21-06 REV 10).

LH WING UPPER SKIN HAS CORROSION AFT OF VORTEX GENERATOR BETWEEN RIBS 22 AND 23. NOMINAL THICKNESS .080" OUT OF LIMITS (REF EMB120 SRM 57-20-01 AND 57-00-01 REV 58). CUTOUT BLENDED AREA (IAW EMB120 SRM 57-20-01 REV 58). LAYED OUT AND FABIRCATED DOUBLER FROM .080" 2024T3. INSTALLED DOUBLER (PER EMB ETD 2019-120-101457 REV 1). APPLIED FILLER SEAL TO DOUBLER, CAP SEALED FASTENERS WITHIN FUEL TANK AND RESTORED ORIGINAL FINISHING OF THE REPAIR AREA (PER EMB ETD 2019-120-101457 AND EMB120 SRM 51-22-00 REV 58).

LH WING UPPER SKIN HAS CORROSION AFT OF THE VORTEX GENERATOR AT RIB 23. NOMINAL THICKNESS .080" OUT OF LIMITS (REF EMB120 SRM 57-20-01 AND 57-00-01 REV 58). CUTOUT BLENDED AREA (IAW EMB120 SRM 57-20-01 REV 58). LAYED OUT AND FABIRCATED DOUBLER FROM .080" 2024T3. INSTALLED DOUBLER (PER EMB ETD 2019-120-101457 REV 1). APPLIED FILLER SEAL TO DOUBLER, CAP SEALED FASTENERS WITHIN FUEL TANK AND RESTORED ORIGINAL FINISHING OF THE REPAIR AREA (PER EMB ETD 2019-120-101457 AND EMB120 SRM 51-22-00 REV 58).

CENTER LONGITUDINAL FLOORBEAM UPPER STILL BETWEEN FRAMES 13-16 HAS AREAS OF CORROSION. REMOVED CORROSION ON CENTER FLOORBEAM UPPER SILL BETWEEN FR 13-16 (IAW EMB120 CPM 51-14-00 REV 10). REMAINING THICKNESS .030 (IAW EMB120 SRM 53-10-10, 53-00-00 REV 58). MATCH DRILLED NEW PART (PER EMB120 SRM 51-40-06 REV 58). INSTALLED NEW CENTER LONGITUDINAL FLOORBEAM UPPER SILL (IAW EMB120 SRM 51-40-02 REV 58).

RH LONGITUDINAL FLOORBEAM UPPER SILL BETWEEN FRAMES 13-15 HAS AREAS OF CORROSION. MATCHDRILLED NEW FLOORBEAM UPPER SILL (REF EMB120 SRM 51-25-00 REV 58). INSTALLED NEW UPPER SILL (REF EMB120 SRM 51-40-02 REV 58).

LEFT LONGITIDUNAL FLOORBEAM UPPER SILL BETWEEN FRAMES 15-16 HAS AREAS OF CORROSION. MATCHDRILLED NEW UPPER SILL (PER EMB120 51-40-02 REV 58). INSTALLED NEW UPPER SILL (PER EMB120 51-40-02 REV 58).

FRAME 17 FAILSAFE BETWEEN STRINGERS 20R-21R HAS CORROSION. MIN REMAINING THICKNESS .027" (REF EMB NDI 51-00-04 REV 3). DRILLED NEW FAILSAFE (IAW EMB120 SRM 51-26-00 REV 58). INSTALLED NEW FAILSAFE (IAW EMB120 SRM 51-40-02 REV 58).