TheSikorsky S-92 is an American twin-engine medium-lifthelicopter built bySikorsky Aircraft for the civil and military helicopter markets. The S-92 was developed from theSikorsky S-70 helicopter and has similar parts such as flight control and rotor systems.
TheH-92 Superhawk is a military version of the S-92 in the utility transport role, capable of carrying 22 troops. The H-92 can also be configured for specific missions, includingsearch and rescue and executive transportation. TheCH-148 Cyclone is a shipboard maritime helicopter variant developed for theRoyal Canadian Air Force to support naval operations of theRoyal Canadian Navy. TheSikorsky VH-92 is a variant under development to replace theUnited States Marine Corps'Marine One U.S. Presidential transport fleet.
After the1973 oil crisis, major oil and gas companies began exploration further offshore, thus creating a need for aircraft such as the S-92 with sufficient capability.[2]
Sikorsky Aircraft first displayed a S-92 mockup of the planned helicopter in 1992. The S-92 was to be offered for sale beginning in 1993, but due to a decline in the international market for helicopters, this was delayed. In 1995 Sikorsky formed Team S-92 with international partners and launched the helicopter program at the Paris Airshow that year.[3] Sikorsky developed the S-92 to compete with civil aircraft such as theAerospatiale/Eurocopter Super Puma.[4] The helicopter uses a new airframe with dynamic components based on theS-70/H-60 components. The S-92 took its maiden flight on December 23, 1998 at the Sikorsky Development Flight Center, West Palm Beach, Florida.[4][5]
In July 2000,Sikorsky announced design changes to the S-92. The fuselage of prototype #3 was lengthened by 16 in (40 cm) aft of the cockpit, the tail pylon was shortened by 41 in (1.04 m), and the horizontal stabilizer was repositioned from the left side opposite the tail rotor to the right side at the base of the tail pylon. The modifications to the tail solved a pitch stability issue discovered during flight testing, and were reported to allow the aircraft to meet a key requirement of theNordic Standard Helicopter Program (NSHP) for shipboard stowage. The lengthening of the fuselage and shortening of the tail pylon shifted the aircraftcenter of gravity (CG) forward, permitting a more level attitude in flight. The longer fuselage allowed for an additional row of three seats, as well as a larger passenger door option for Search and Rescue (SAR) customers. Sikorsky incorporated the changes into the following two prototypes as the production standard configuration.[6] Some reports suggested that the modifications were actually to resolve damage from structural design flaws.[7]
In February 2007, the thenUnited Technologies Corporation's subsidiary, Sikorsky Aircraft Corporation and India'sTata Advanced Systems (TASL) signed aMemorandum of Understanding (MoU) to create opportunities for aerospace operations in India.[10] On June 12, 2009, Sikorsky signed an agreement with TASL for manufacturing helicopter cabins of S-92(R) inIndia for export and domestic markets. The first cabin would be delivered in late 2010 from a new greenfield manufacturing facility nearHyderabad, the then capital ofAndhra Pradesh.[11][12][13] On November 12, the companies signed another agreement to form ajoint venture (which led to the formation Tata–Sikorsky Aerospace Limited)[14] to manufacture aerospace components in India. The venture would be open to manufacture components for otherOEMs in the aerospace sector as well. The joint venture's operations would be based in a second greenfield facility beside the cabin manufacturing building. The construction of the second facility, initially meant for production of over 5,000 "detailed aerospace components",[15] is scheduled for completion by 2011 with production commencing from 2012.[10][16]
The first consignment of S-92 cabins was delivered in November 2010. The facility is located in theSpecial Economic Zone (SEZ) inAdibatla.[17] As of April 2012, Sikorsky planned to double the manufacturing capacity of helicopter cabins in the Hyderabad facility. The enhanced capacity would be enhanced in a phased manner with two cabins per month in June 2012 and then to 3 cabins per month or 36 units annually in December 2013. The workforce would be increased to match the planned capacity.[18][19] As of May 2015, the joint venture was also producing 4,000 components besides the cabins which is expected to achieve an indigenous content of 80% by 2013. There were also plans to establish a helicopter manufacturing facility with a capacity of 2–3 S-92 helicopters monthly after 2015–16 in addition to other manufacturing facilities in China, Holland, Turkey and Columbia and other South American countries.[20] On October 24, 2013, the joint venture delivered the first fully indigenous S-92 cabin which would be then shipped to the US for final assembly and delivery. Meanwhile, the company delivered the 50th cabin earlier that month. Its production capacity had been increased to four cabins per month in the first facility along with 5,000 different components in the second facility.[15][21]
The S-92 is multi-purpose helicopter powered by twinGE CT7-8A turboshaft engines and has an aluminum airframe and some composite components. The four-bladed fully articulated composite main rotor blade is wider and has a longer radius than the Sikorsky S-70. The tapered blade tip sweeps back and angles downward to reduce noise and increase lift. Most of the rotor system components aside from the blades are titanium.[citation needed]
The S-92 features anactive vibration control system, using vibration sensors and structurally mounted force generators to increase flight comfort and lower acoustic levels to below certification requirements.[22] A 2008 study by Norway'sFlymedisinsk Institute found that the S-92's vibration levels were 42 percent above that of theEurocopter EC225 Super Puma; Sikorsky disputed this finding, saying that the study hadn't used their latest anti-vibration technology.[23] In February 2011, as published on a Norwegian newspaper's website, the noise and vibration levels were reportedly subject to health concerns, allegedly causingtinnitus and heart problems.[24][25]
A number of safety features such as flaw tolerance,bird strike capability, and engine burst containment have been incorporated into the design. Adherence to FAA FAR part 29 has led the FAA certification board to call the S-92 the "safest helicopter in the world".[26] The S-92 was not able to meet theFederal Aviation Regulation "run dry" specification for loss of oil pressure in the main gearbox, but was certified with an exemption due to the unlikelihood of such a situation occurring; this was a factor in the fatal crash ofCougar Helicopters Flight 91 in 2009.[27]
The S-92 received FAA certification in 2002,[8] and International certification in June 2004.[9] The first S-92 was delivered in late 2004 to launch customerPHI, Inc.[28][29]
After Sikorsky successfully challenged in court the preferred supplier status of NHIndustries NH90 for the Nordic Standard Helicopter Programme an open competition was held.[32] Sikorsky entered the S-92 as a candidate for the Norwegian All Weather Search and Rescue Helicopter (NAWSARH) that is planned to replace theRoyal Norwegian Air ForceWestland Sea King Mk.43B in 2015.[33] The other candidates for the NAWSARH contract of 10 to 12 helicopters wereAgustaWestland AW101,Bell Boeing V-22 Osprey,Eurocopter EC225, andNHIndustries NH90.[34] The V-22 was eliminated from the competition in 2012.[35] The S-92 was removed from the competition in July 2013 and was subsequently won by AgustaWestland with an order for 16 AW101s.[32]
The S-92 competed with the Eurocopter EC225 for the UK Search and Rescue – Helicopter (SAR-H) program.[36] In February 2010, the S-92 was selected by the UK in a £6bn deal to replace 40 Sea King search and rescue helicopters with 25 to 30 S-92s;[37] it subsequently announced that Soteria, the preferred supplier, will not be used due to irregularities with its bid.[38] The UK government subsequently opted for a smaller £2.5bn contract with the Bristow Group to operate 11 S-92s (and 11 AW189s) from 10 bases.[39]
In the wake of the deadly2016 crash of aEurocopter EC225 Super Puma contracted byStatoil, that company announced that it would not use that type again and instead use the Sikorsky S-92 to meet its needs, stipulating that operators it contracts with, such asCHC Helikopter Service, will be required to use such equipment.[41]
The S-92A is the civilian variant and is available in a number of versions. The civil transport version has an airliner-type interior that seats 19 passengers. The utility transport version has 22 side-facing seats with a full cabin width rear ramp. The 700 cu ft (20 m3) cabin volume can also be configured to accommodate up to three airline-styleLD3 cargo containers. Additional stowage space is available in the 140 cu ft (4.0 m3) volume located in the aft ramp compartment. During development it was referred to as the S-92C Helibus.
The H-92 Superhawk is the military variant of the S-92. It has been demonstrated to the U.S. Air Force, Marine Corps and Coast Guard. The H-92 has more powerful GE CT7-8C engines, rated at 3,070 shp (2,290 kW) and, unlike the S-92, hasfly-by-wire flight controls. The search and rescue variant provides space for seats,litters,auxiliary fuel cell and SAR emergency equipment.
In July 2004, the H-92 Superhawk was selected byCanada for its Maritime Helicopter Programme (MHP) as theCH-148 Cyclone. Canada ordered 28 helicopters in November 2004.[42] The program has been delayed multiple times.[43] As of November 2019, nineteen CH-148 Cyclones have been built, delivered, and accepted by the government of Canada. The Canadian military declared initial operational capacity in June 2018, and expects full operational capacity by fall 2025.[44]
On July 2, 2008, an S-92A servicing an oil platform in Australia lost gearbox oil pressure due to fractured oil pump studs and was forced to make an emergency landing.[81] This incident led to Sikorsky issuing a notice to replace titanium gearbox studs with steel studs. This refit had not yet been conducted on the Cougar Helicopters S-92 that crashed the following year.[citation needed]
On July 19, 2008, an S-92 carrying Rev.Sun Myung Moon crashed in South Korea.[82] The helicopter was flying in inclement weather that forced it down on a hillside. The 16 people aboard were slightly injured in the crash.[83][84]
On March 12, 2009,Cougar Helicopters Flight 91, an S-92A operated byCougar Helicopters carrying 18 passengers and crew en route to oil platforms off the coast of Newfoundland, crashed and sank in 170 meters (560 ft) of water[85] during an attempted ditching. One person was rescued from the North Atlantic with serious injuries[86] and the others did not survive.[87] The crash was determined[88] to be caused by 16 separate factors. The primary cause was galling or fracture of titanium gearbox studs that had not yet been replaced with steel.[89]
On December 28, 2016, a S-92 (registration G-WNSR, serial number 920250[90]) operated byCHC Helicopter experienced "unexpected control responses" whilst in mid-air on a routine shuttle flight between two oil installations in theNorth Sea. The pilots conducted an emergency landing on theWest Franklin platform.[91] The helicopter is reported to have spun on the helideck during the landing, damaging the helicopter wheels and rotor blades.[92] The helideck also sustained damage during the emergency landing.[92] There were no reported injuries amongst the nine passengers and two crew during the incident.[91] The aircraft was transported back to Aberdeen via ship, at which time theAir Accidents Investigation Branch began their investigation into the incident.[93] Sikorsky issued a notice on January 9, 2017 grounding all S-92 aircraft until the tail rotors have been inspected. The inspection work takes approximately 11 man hours to complete.[94] The Air Accidents Investigation Branch issued an update on January 11, 2017 that reported that the tail rotor pitch change shaft bearing had seized. The bearing showed signs of severe overheating and significant wear. The failure of the bearing allowed the tail rotor driveshaft to damage the tail rotor servo. The damage to the tail rotor servo is considered to be the cause of the loss of tail rotor control. Thehealth and usage monitoring systems had discovered the flaw the day before flight, but the maintenance crew had not.[95]
On March 14, 2017, aS-92 operated by CHC Helicopter under contract to theIrish Coast Guard crashed off the west coast of Ireland with four crew members on board. Three of the crew were initially missing. CaptainDara Fitzpatrick was recovered from the water but later died in hospital.[96] The helicopter crashed into an unmapped island in poor weather. The helicopter fuselage was located.[97] Captain Mark Duffy's body was recovered in the helicopter's cockpit on March 26.[98]
On February 28, 2024, a Bristow Group S-92 search and rescue helicopter crashed west ofBergen, Norway with six crew and passengers onboard.[99] While all crew and passengers survived the crash itself, one person died from being left in the sea for too long.[citation needed]
^Lake, Jon, editor."Type Focus: Sikorsky S-92"Archived December 11, 2008, at theWayback Machine.RotorHub. Shepard Publishing. October–November 2007. p. 19. Accessed: 8 November 2008. The article suggests that reasons for the design modifications on the S-92 were the result of cracking on the tail pylon and stabilator based on reports from unnamed industry sources.
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