INTEGRA AVIATION LLC

Operated by Integra Aviation LLC (per NTSB report)

Operated by Integra Aviation LLC. (per NTSB report)

DURING CLIMBOUT, LOUD BRIEF BUZZING NOISE HEARD. CREW STARTED SMELLING A CHARRING SMELL. CHARRING SMELL INCREASED WHILE ON THE GROUND. MAINTENANCE CREW TROUBLESHOT. EXTERNAL HYDRO POWER WAS APPLIED TO ATTEMPT TO IDENTIFY THE SERVO. COULD NOT REPLICATE THE CHARRING SMELL. THE BUZZING WAS DUE TO THE CYCLIC SPRING LINK HOUSING BEING OVERTIGHTENED. REMOVED, DISASSEMBLED, REASSEMBLED AND REINSTALLED CYCLIC SPRING. SUBSEQUENT CHECK FLIGHT RESULTED IN NO DEFECTS NOTED.

DURING FLIGHT CABIN AND COCKPIT HAD EXCESSIVE GAS FUMES. PILOT REPORTED FAILED FIRST START ATTEMPT. SECOND START WAS SUCCESSFUL PRIOR TO DEPARTING FOR SCHEDULED FLIGHT. UPON RETURN NOTED PRESENCE OF RESIDUAL FUEL ON AFT ENGINE COWLING, CLAMSHELL DOOR, AND R/H AIRFRAME BODY. INSPECTED DRAIN PIPE OF THE DRAIN TANK FOR OBSTRUCTIONS AND NOTED MINOR OBSTRUCTION. CLEARED OBSTRUCTION AND RECONNECTED. INSPECTED AIRFRAME EQUIPMENT PLATES FOR LEAKAGE. NO LEAKS NOTED. INSPECTED ENGINE FUEL AND FUEL DRAIN COMPONENTS FOR LEAKAGE. NO LEAKS NOTED. CLEANED RESIDUAL FUEL FROM AIRFRAME AND AIRFRAME DRAINS. PERFROMED GROUND RUN WITH NO DEFECTS NOTED AT THIS TIME.

THE AIRCRAFT WAS OPENED UP FOR PHASE INSPECTION ON 1/15/2026. UPON INSPECTION, THE RIGHT WING AND LEFT WING INBOARD FLAP, OUTBOARD FLAP TRACKS WERE CRACKED AND SEPARATED BY APPROXIMATELY 1/2". TRACKS BRACKET- OUTBOARD FLAP TRACK. BEECHCRAFT/TEXTRON HAS BEEN NOTIFIED OF THE TRACK FAILURE.

CREW OBSERVED SMOKE IN CABIN WITH HEATER ON CLIMB-OUT. THE PIC DECIDED TO ABORT THE FLIGHT AND RETURN TO STARTING POINT. UPON INVESTIGATION, IT WAS DISCOVERED THAT THIS WAS THE FIRST TIME THAT HEATER HAS BEEN TURNED ON SINCE THE SPRING MONTHS. LINT AND DUST WITHIN THE HEATER CAUSED THE BURNING SMELL. THE ASSISTANT CHIEF PILOT SAID THAT THIS IS COMMON WITH ALL KING AIR 90'S WITH AN ELECTRIC HEATER.

AIRCRAFT WAS ENROUTE TO SENDING FACILITY AND EXPERIENCED A FADEC MANUAL CAUTION LIGHT WITH A FEW OTHER INDICATOR LIGHTS ON THE #2 SIDE GOING OFF. HE IMMEDIATELY DECIDED TO DIVERT AND MAKE A PRECAUTIONARY LANDING AT KINT. UPON TRYING TO LAND THE FADEC DID FAIL AND ONCE HE SWITCHED TO MANUAL BOTH ENGINES FAILED. PIC SAID THAT THE #1 SIDE DIDN'T GIVE ANY INDICATION OF FAILURE PRIOR TO THAT. HE INITIALLY WAS ATTEMPTING TO WORK THE PROBLEM ON THE #2 SIDE AND DIDN'T EXPECT THAT IT WAS THE REVERSE PROBLEM WITH THE #1 SIDE. THE A/C DID EXPERIENCE A HARD LANDING AND THERE IS DAMAGE TO THE REAR SKID. AT THIS TIME, APOLLO MEDFLIGHT IS STILL INVESTIGATING THIS INCIDENT. THE AIRCRAFT IS BEING MOVED TO A FACILITY FOR REPAIRS. AT THAT TIME WE WILL FIND THE REASON FOR THE FADEC ISSUES AND ENGINE STOPPAGE.

CREW NOTICED FAINT SWEET, RUBBERY, BURNING SMELL IN AFT CABIN. THE AIRCRAFT DIVERTED TO A PAFFORD BASE IN CLARKSDALE, MS. REMOVED HAT RACK STORAGE BIN TO GAIN ACCESS TO ELECTRICAL CONNECTORS AND AFT AVIONICS SHELF. INSPECTED ALL ELECTRICAL CONNECTORS AND FOUND NO DAMAGE. INSPECTED AIRCOMM PULLY AND BELT NO SIGNS OF SLIPPAGE OR DAMAGED FOUND. REMOVED AFT AVIONICS SHELF ACCESS PANEL TO INSPECT BLOWER MOTOR ASSEMBLY AND ELECTRICAL CONNECTORS. NO SIGNS OF DAMAGE FOUND. COMPLETED 10-MINUTE GROUND RUN AND COULD NOT DUPLICATE SMELL.

WHILE PASSING OVER A 5G COMMUNICATIONS TOWER, JUST EAST ON HCA KINGWOOD HOSPITAL, KINGWOOD, TX, THE HELICOPTER HAD AN ARRAY OF CAUTIONS WITH THE GENESIS. THE PIC STATED, “JUST STARTED THROWING ALL KINDS OF CAUTIONS ON THE GENESIS AND THEN KICKED OFF MY UPPER MODES”. THE PILOT DID NOT TAKE ANY EVASIVE ACTION, FLEW THE HELICOPTER MANUALLY UNTIL ALL OF THE CAUTIONS EXTINGUISHED AND THE AVIONICS RETURNED TO NORMAL. THIS IS A KNOWN ISSUE WITH GENESYS AND 5G.

DURING FLIGHT, A DISTINCT FUEL SMELL COMING FROM AFT RIGHT SEAT AREA. SMELL WAS STRONG ENOUGH TO MAKE MEDICAL CREW MEMBER WHO IS SITTING IN THAT SEAT NAUSEOUS. PILOT DID NOT SENSE ANY FUEL FUMES. AMT REMOVED STRUCTURAL ACCESS PANELS FOR FUEL SHUT OFF VALVE R/H COMPARTMENT TO INVESTIGATE THE FUEL SMELL. NOTED FUEL SMELL COMING FROM FUEL SHUT OFF VALVE R/H COMPARTMENT. NO ACTIVE LEAK NOTED AT THIS TIME. THE AMT REMOVED DEBRIS OBSTRUCTING VENT PORT OF SHUT OFF VALVE. INSTALLED AND SEALED QUANTITY 2 STRUCTURAL ACCESS PANELS WHICH WERE NOT SEALED PROVIDING MINIMAL FUME PROTECTION. A CHECK FLIGHT WAS PERFORMED WITH NO FUEL FUMES.

WHILE ENROUTE TO SENDING FACILITY FOR PATIENT PICKUP PIC ADVISED COMM CENTER THEY WOULD BE ABORTING FLIGHT DUE TO CREW SMELLING SMOKE. PIC MADE A PRECAUTIONARY LANDING IN A SECURE FIELD. THE MECHANIC PERFORMED TROUBLESHOOTING AND FOUND A BAD AFT BLOWER MOTOR.

PIC WAS 15 MILES NORTH OF LAREDO, ENROUTE TO SAN ANTONIO WITH PATIENT WHEN PIC TURNED AROUND. COMMS ADVISED THAT PIC HAD DECLARED AN EMERGENCY AND LOST HIS FUEL PUMPS. CALLED PIC AFTER LANDING SAFELY BACK AT LAREDO, HE ADVISED THAT THEY HAD LOST THE FORWARD FUEL PUMP AND THE AFT FUEL PUMP WAS ALREADY MEL'D, SO HE WAS BEING NOTIFIED BY THE AIRCRAFT THAT HE ONLY HAD 20 MINS OF FUEL REMAINING. SAFE ON DECK, MTX NOTIFIED. CREW TRANSPORTING PATIENT BACK TO HOSPITAL. THE MECHANIC FOUND FWD XSFER PUMP WIRING SHOWING SIGNS OF CHAFFING. CUT OFF BOTH CHAFFED AREAS AND RETERMINATED WIRES.

RIGHT TRANSMISSION PRESSURE INDICATOR TURNED RED AND WENT DOWN TO 0, PIC DECLARED AN EMERGENCY TO WILMINGTON TOWER. PIC WENT INTO HOVER AND THE ALERT WENT BACK TO NORMAL FOR A MOMENT THEN WENT RIGHT BACK TO RED. PILOT LANDED SAFELY IN A FIELD, COMS CANCELED EMERGENCY WITH WILMINGTON TOWER. THE MECHANIC FOUND THE RIGHT OIL PRESSURE TRANSMITTER CONNECTOR DIRTY. CONNECTOR WAS CLEANED AND OPERATIONAL CHECKS WERE FOUND SATISFACTORY.

JUST A FEW MILES AFTER TAKING OFF FROM BASE, PIC ADVISED OVER RADIO THAT THEY WOULD BE HEADED BACK TO KGRI DUE TO THE CREW SMELLING FUMES IN THE CABIN. ONCE LANDED PIC CONTACTED OCC AND ADVISED CREW WAS SMELLING OIL/EXHAUST LIKE FUMES AND IT STARTED TO MAKE THEM NAUSEOUS. PIC ADVISED SMELL WAS ONLY IN CABIN AREA AS HE DID NOT SMELL ANYTHING IN THE COCKPIT. THE MECHANIC CLEANED AND INSPECTED THE AFT AC SYSTEM DUCTS AND EVAPORATOR. OPERATIONAL CHECK WAS PERFORMED WITH NO DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

PILOT REPORTED SMELLING FUEL DURING FLIGHT. UNSCHEDULED LANDING AT TUNICA AIRPORT (KUTA). PERFORMED POST-FLIGHT WALK AROUND AND FOUND FUEL ON THE R/H SIDE OF THE AIRCRAFT. PERFORMED INSPECTIONS, GROUND RUNS AND AN IN FLIGHT CHECK. COULD NOT FIND THE SOURCE OF THE LEAK AND COULD NOT DUPLICATE THE ISSUE. SUSPECT FUEL CAP WAS NOT SECURED PROPERLY.

FOUND CRACKING ON EACH BRAKE CALIPER PISTON. WEAR PLATES DO NO COMPLETELY SPAN PISTON. FOUND ABNORMAL WEAR ON HOUSING FROM CONTACT WITH PADS AND ROTOR DISK. THIS IS THE SECOND INSTANCE.

AIRCRAFT WAS ENROUTE FROM MONTICELLO MUNICIPAL AIRPORT FOR A PATIENT TRANSPORT. 10 MINUTES INTO THE FLIGHT, THE CREW REPORTED FUMES IN THE CABIN AREA. THE PIC DECIDED TO MAKE AN UNSCHEDULED LANDING AT MCGEHEE MUNICIPAL AIRPORT AS A PRECAUTIONARY MEASURE TO HAVE THE AIRCRAFT CHECKED OUT BY MAINTENANCE PERSONNEL. WHEN MAINTENANCE PERSONNEL ARRIVED, RAGS WERE FOUND IN FRONT OF THE HEATER OUTLET DUCTS. THE RAGS WERE REMOVED, THE AIRCRAFT WAS INSPECTED AND A COMPLETE FUNCTIONAL TEST OF THE HEATER SYSTEM WAS PERFORMED ON THE GROUND WITH THE ENGINE RUNNING. IT WAS DETERMINED THAT THE SOURCE OF THE FUMES WERE THE RAGS IN FRONT OF THE HEATER DUCTS. NO OTHER DEFECTS WERE FOUND. THE AIRCRAFT HAS FLOWN 2.6 HOURS SINCE THIS INCIDENT WITH NO REPEAT/RECUR OF THE FUMES IN THE CABIN AREA.

SMOKE IN THE CABIN AFTER 5 MINUTES OF FLIGHT, SIGNIFICANT SMELL. THE SMOKE DID DIMINISH AFTER HEAT WAS TURNED OFF AND AC TURNED ON. CORRECTIVE ACTION: INSPECTED AND CLEANED AREA AROUND HEATER VENTS. PERFORMED GROUND RUNS WITH NO DEFECTS NOTED. UNABLE TO DUPLICATE ANY ISSUES.

WHILE ENROUTE TO KLVS FROM KGUY, THE GARMIN GNS530W SCREEN SHUT OFF. WHILE TROUBLESHOOTING, A STRONG ELECTRICAL SMELL FILLED THE CABIN. THE AIRCRAFT DIVERTED TO KTDW FOR FURTHER EVALUATION BY THE MAINTENANCE TEAM. UPON FURTHER EVALUATION, IT HAS BEEN DETERMINED THAT THE MALFUNCTION WAS ISOLATED TO THE GARMIN GNS 530. THERE IS NO EVIDENCE OF ANY OTHER BURNING, MELTING OR SHORTING WITH THE ASSOCIATED EQUIPMENT.

AFTER LEVELING OUT FROM TAKE-OFF FROM KSAT TO HOUSTON THE LOW RPM WARNING LIGHT WITH AUDIO STARTED GOING OFF. I VERIFIED THE WARNING BY OBSERVING ROTOR RPMS BELOW 95% ON THE TRIPLE TACH. I IMMEDIATELY REDUCED POWER RESULTING IN LITTLE EFFECT ON THE RPMS. I CONTACTED KSAT TOWER TO RETURN TO THE AIRPORT. BEING IN A NEW AIRCRAFT AT AN UNFAMILIAR AIRPORT I DECLARED AN EMERGENCY TO BE ABLE TO MANEUVER SAFELY AS NEEDED. ONCE AT A HOVER RPM'S STABILIZED IN THE APPROPRIATE RANGE WITH NO INDICATION OF FAILURE AND I RETURNED TO THE SKY CARE HANGAR