In aviation maintenance, every detail counts—especially when it comes to turbine engines. Even the smallest mistakes rarely stay small and can jeopardize engine health and safety. This is why engineers must be meticulous in their approach to Foreign Object Debris (FOD) prevention.
The Incident We Can’t Ignore
Earlier this year, a Bell 206L4 helicopter (source: Aerossurance) was forced to ditch in icy waters off Greenland after a chip detector light illuminated, followed by an engine failure. Partial failure of its emergency flotation system caused even more distress as the helicopter rolled over in the water. But that wasn’t the whole story.
The accident investigation showed a separated tab from a tab washer lodged in the scavenge oil pump, causing the drive shaft to shear. The return oil flow was lost, and the oil pressure as well. Engine bearings started to degrade immediately as the engine was still operating. Eventually, the engine power was lost, and the engine failed.
In this case, the FOD came from the engine itself, but it serves as a stark reminder of the dangers of FOD in oil systems.
The Hidden Dangers of FOD
FOD contamination is a silent threat. Small debris entering the turbine oil unnoticed can cause severe damage to engine components. These tiny particles contribute to abnormal wear, bearing damage and overheating of the bearing, and, in extreme cases, catastrophic engine failure.
FOD Starts with the Little Things
If you’ve ever serviced a turbine engine, you know how easy it is for things to go wrong:
- I don’t have a proper can opener, so I use a screwdriver.
- The funnel for filling is dirty, and I don’t care to clean it.
- The oil cans are full of dirt on the top, but it is just small stuff. I leave the ope,n half-full oil can on my workbench without a cover.
Are you taking chances you don’t need to? Here’s the reality: You don’t want “false” chip warning lights constantly triggered by improper maintenance actions, like using screwdrivers or pliers to open turbine oil cans.
The RR250 engine runs at 56,000 RPM. You don’t get minutes to react. You get seconds.
If you’re used to seeing chip lights triggered by non-engine-related material – debris from turbine oil can material, or chrome fragments from inappropriate tools – you might ignore the next one, assuming it’s just another false alarm.
You will lose valuable time thinking it’s just another ‘false’ chip warning for the mechanic to wipe and clear. Instead, you should already be concentrating on emergency procedures and keeping your rotor RPM in the green.
These oversights don’t just cost money—they cost decision-making time when it matters most.
What Greenland Teaches Us
The Bell 206L4 incident reminds us that keeping a clean oil system will give you engine-related chip warnings. Using TheCanKey FOD prevention products will protect your oil system so you can concentrate on your emergency procedures.
Remember – FOD isn’t always obvious, and its consequences aren’t always immediate.
That’s why FOD prevention tools need to be standard practice, not optional gadgets. And why do we need to shift from reactive responses to deliberate choices that prevent contamination before it occurs.
Final Thought
Aviation safety is built on thousands of small decisions. Let’s raise the standard of what we expect during maintenance—and what we equip our teams with to meet that standard.
We need strict FOD management protocols and dedicated tools to eliminate FOD risks. Let’s work together to safeguard aviation safety. If you’re serious about aviation safety—and I know many of you are—this is one small change that can make a big difference. Take control of your FOD prevention today.
