A prototype S92 helicopter at 500 ft on a test flight had the rotor 'beanie' depart the aircraft. Caused by incorrect mounting fasteners.

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Attributes
ACN	607590
Time
Date	200402
Day	Sat
Local Time Of Day	1201 To 1800
Place
Locale Reference	airport : zzz.airport
State Reference	US
Altitude	agl single value : 500
Environment
Flight Conditions	VMC
Light	Daylight
Aircraft 1
Controlling Facilities	tower : zzz.tower
Operator	general aviation : corporate
Make Model Name	Sikorsky Helicopter Undifferentiated or Other Model
Operating Under FAR Part	Part 91
Flight Phase	cruise : level
Flight Plan	VFR
Person 1
Affiliation	company : corporate
Function	flight crew : captain oversight : pic
Qualification	pilot : multi engine pilot : instrument pilot : commercial pilot : cfi pilot : atp
Experience	flight time last 90 days : 65 flight time total : 5400 flight time type : 800
ASRS Report	607590
Person 2
Affiliation	company : corporate
Function	flight crew : first officer
Events
Anomaly	aircraft equipment problem : critical maintenance problem : improper maintenance maintenance problem : improper documentation non adherence : published procedure non adherence : far
Independent Detector	other flight crewa other flight crewb
Resolutory Action	none taken : detected after the fact
Consequence	other other
Factors
Maintenance	performance deficiency : logbook entry performance deficiency : installation performance deficiency : non compliance with legal requirements
Supplementary
Problem Areas	Maintenance Human Performance Aircraft
Primary Problem	Maintenance Human Performance

Narrative:

Departed ZZZ VFR to the west under tower control. Remained south of blvd below 500 ft. Coordinated on this track for approximately 25 mi. Reversed course and returned to ZZZ via the same route and altitude. Upon landing we discovered a 3 ft main rotor 'beanie' was missing. Callback conversation with reporter revealed the following information: the reporter said while on a 50 mi test flight the main rotor 'beanie' departed the aircraft and was discovered missing when back on the ground. The reporter stated the loss of the rotor 'beanie' had no effect on the flight characteristics of the machine. The reporter said the 'beanie' is a 36 inch circular aerodynamic fairing shaped like a frisbee that covers the top of the rotor shaft hub and performs an aerodynamic function and protects rotor deicing wiring. The reporter stated engineering investigated the incident and found the wrong mounting fasteners were installed and had failed.

Original NASA ASRS Text

Title: A PROTOTYPE S92 HELI AT 500 FT ON A TEST FLT HAD THE ROTOR 'BEANIE' DEPART THE ACFT. CAUSED BY INCORRECT MOUNTING FASTENERS.

Narrative: DEPARTED ZZZ VFR TO THE W UNDER TWR CTL. REMAINED S OF BLVD BELOW 500 FT. COORDINATED ON THIS TRACK FOR APPROX 25 MI. REVERSED COURSE AND RETURNED TO ZZZ VIA THE SAME RTE AND ALT. UPON LNDG WE DISCOVERED A 3 FT MAIN ROTOR 'BEANIE' WAS MISSING. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR SAID WHILE ON A 50 MI TEST FLT THE MAIN ROTOR 'BEANIE' DEPARTED THE ACFT AND WAS DISCOVERED MISSING WHEN BACK ON THE GND. THE RPTR STATED THE LOSS OF THE ROTOR 'BEANIE' HAD NO EFFECT ON THE FLT CHARACTERISTICS OF THE MACHINE. THE RPTR SAID THE 'BEANIE' IS A 36 INCH CIRCULAR AERODYNAMIC FAIRING SHAPED LIKE A FRISBEE THAT COVERS THE TOP OF THE ROTOR SHAFT HUB AND PERFORMS AN AERODYNAMIC FUNCTION AND PROTECTS ROTOR DEICING WIRING. THE RPTR STATED ENGINEERING INVESTIGATED THE INCIDENT AND FOUND THE WRONG MOUNTING FASTENERS WERE INSTALLED AND HAD FAILED.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.