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The Unexpected Drop of MP at 12K Ft

alexnor

New member
Kissimmee, FL
Aircraft Year
1978
Aircraft Type
112TCA
Reg Number
N4676W
Serial Number
13252
I share yesterday’s declared emergency in the hopes that it can help anyone encountering anything similar in the future.

I fly a 1978 112TCA.

At 10:53am my wife and I departed Kissimmee, FL on an IFR flight to Gulfport, MS with an intended fuel stop at Atmore, AL. Cruise altitude was 8,000.

I recently had a GDC 31 GPSS installed but it was acting up so could not use it. Since it depends on the heading bug, I could not use that either with the autopilot.

Although we were supposed to fly over Cross City, we had to go further east as XM showed bad weather from Cedar Key inland all the way up to South GA. This was clearly visible when we got to the area. The majority of cumulous clouds where topping 8,000 to 11,000 and there was some heavy precip.

Once we curved around it, we took our turn to the west. To make things a little more comfortable I requested clearance to 12,000 so we could be over the clouds. We adjusted our oxygen flow and were doing a nice cruise at 65% 147 TAS.

We were north of Quincy Municipal on the GA side when it suddenly happened. Manifold pressure dropped from 31.4 to 20 with a very clear sound of the engine slowing. Fuel flow went from 11 GPH down to 7. After the 2 seconds of Oh Sh..t past, I immediately turned on the electric fuel pump but no change. Pushed the throttle forward and it got worse. Pulled the alternate air and the engine didn’t like that either. Mixture forward no good either. Mixture back to where it was, stable. Checked fuel and it was ok. Of course, this could be caused by several different problems and I was not going to be able to figure it out in flight.

I advised my wife we had a real problem and immediately declared an emergency to approach control. They offered several airport options. I looked at ForeFlight on my iPad, which is attached to the yoke, and saw pink airports within gliding distance and Tallahassee which was blue. Although Tallahassee was not within my gliding radius I knew with the left over power I had I was close enough to at least get into gliding distance within a couple of minutes. This was important because I wanted an airport with emergency services and I did not know for how long the engine would stay on.

Tallahassee was reporting 3,000 foot ceilings. The broken clouds where tight packed with tops at 11,000 and there was no choice but to go in them. That was the longest 30 mins or so of decent having to hand fly, in the soup, approach vectors inside 8,000 feet of clouds while trying to keep 100 kts for Va for our weight. With the stress of it all it took every ounce of instrument flying focus I had. My wife stayed remarkably calm dropping some tears, praying to herself and texting instructions to her uncle in case of the worst happened.

Tallahassee offered an ASR approach and I advised him I did not want to descend to approach minimums until I was close enough to ensure ample glide distance. At about 4,000 feet I saw a hole in the clouds, I could go through, and there was the airport. I was high so I flew parallel to runway 27 bringing the throttle back a little bit at a time focusing on a glide landing. I asked the controller for the length and elevation of runway 18. It was 7,000 feet long and 18 feet elevation. By the time I turned the downwind of 18 I was flying 3,000 ft. I then turned base at 2000 and final at about 1700. Once I knew I had it, I went full flaps and did a steep descent for what was left. Fire trucks and emergency crews where right there waiting.

My wife said my right hand was shaking and I can tell you my wrist pulse oximeter, which vibrates when I am at or under 93, was vibrating all the way down.

Once the local mechanic inspected the plane we found the turbo waste gate cable had snapped and that was the cause.

I can’t begin to express our gratitude to the Tallahassee approach controller who maintained a steady calm voice while being beyond helpful with every request. Sometimes it is easy to take these guys for granted but they are amazing people that can help save your life.

I realized that one of the best decisions I ever made was getting my instrument rating.

Setting up the glide advisor in ForeFlight also gives you one less thing to think about. Here are the settings for the 112TCA,

Best Glide = 75
Glide Ratio 10.9:1

Please confirm with your own POH.

Hope this helps and safe flying to everyone!

Here is the flight on FlightAware if you want to see it.

https://flightaware.com/live/flight/N4676W/history/20180815/1445Z/KISM/KTLH
 
Re: The Unexpected Drop of MP at 12K Ft

Glad you're safe
 
Re: The Unexpected Drop of MP at 12K Ft

Nice write up and glad it all worked out. You never know but your explanation might just help someone in the future. Nice to learn and better yet from the actual person.

Thanks for taking the time to write it up.
 
Re: The Unexpected Drop of MP at 12K Ft

Thanks for sharing Alex and glad you're OK. Let us know what else you might find out about what caused that wastegate cable to break.
 
Re: The Unexpected Drop of MP at 12K Ft

Thank you for sharing, Alex.

For those symptoms - I would have guessed turbo charger failure.
Wastegate cable - similar results.

Good emergency handling. Good write-up. Glad it worked out.
Its always good to have a calm right seater.
 
Re: The Unexpected Drop of MP at 12K Ft

Great job Alex. Good reminder to practice glide scenarios....

We fight these wastegate cables all the time. Did it break at the rod end or the cable itself? Did you notice it working stiffer than usual in the flights preceeding this one? I know you did a complete overhaul after you bought the airplane. Did they refurb the cable?

Sure would be helpful to us if you got a pic showing the break location before they remove the cable from the airplene.

They don't fly well at 20" do they? k
 
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Re: The Unexpected Drop of MP at 12K Ft

Pardon the ignorance..

But if you lose your wastegate on your turbo... does it not then become normally aspirated? I am assuming the answer is No given what you described but I was trying to understand why. My engine would not be too bad at 20" in other words.

Thanks
 
Re: The Unexpected Drop of MP at 12K Ft

Hi Alex,

Good work!

For those who may set the glide distance in their EFB's, etc, please fly some glides first so you know what YOU can reliably achieve. The book is optimistic on this, as usual.

Jim
 
Re: The Unexpected Drop of MP at 12K Ft

Pardon the ignorance..

But if you lose your wastegate on your turbo... does it not then become normally aspirated? I am assuming the answer is No given what you described but I was trying to understand why. My engine would not be too bad at 20" in other words.

Thanks

The turbocharged TC/TCA engines are dependant on the turbo to make horsepower, so no. They do not become like an n/a plane without it - full power is around 41" mp. The waste gate cable is a critical maintenance item that should be inspected every 50 hours and replaced every other annual.

The turbo normalized engines go back to being n/a if the turbo fails. Will lose some hp at altitude, of course, but go back to the factory numbers/ performance.
 
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Re: The Unexpected Drop of MP at 12K Ft

The turbocharged TC/TCA engines are dependant on the turbo to make horsepower, so no. They do not become like an n/a plane without it - full power is around 41" mp. The waste gate cable is a critical maintenance item that should be inspected every 50 hours and replaced every other annual.

The turbo normalized engines go back to being n/a if the turbo fails. Will lose some hp at altitude, of course, but go back to the factory numbers/ performance.
Ah... gotcha. So the turbo is always on in some degree in all flight operations.
 
Re: The Unexpected Drop of MP at 12K Ft

Ah... gotcha. So the turbo is always on in some degree in all flight operations.

Yes. They squeeze an extra 10 hp out of them by lowering the compression to prevent predetonation and increasing the boost. So, without the turbo spinning they don't have enough compression to make power.

How much can they make without the turbo - I don't know? 100hp? 120? I don't know?
 
Re: The Unexpected Drop of MP at 12K Ft

Yes. They squeeze an extra 10 hp out of them by lowering the compression to prevent predetonation and increasing the boost. So, without the turbo spinning they don't have enough compression to make power.

How much can they make without the turbo - I don't know? 100hp? 120? I don't know?
Got it and makes sense. Thanks
 
Re: The Unexpected Drop of MP at 12K Ft

Yes. They squeeze an extra 10 hp out of them by lowering the compression to prevent predetonation and increasing the boost. So, without the turbo spinning they don't have enough compression to make power.

How much can they make without the turbo - I don't know? 100hp? 120? I don't know?

20 MAP from the experience above.

I fly my approaches at 24" MAP for 95 knots dirty.
 
Re: The Unexpected Drop of MP at 12K Ft

The turbocharged TC/TCA engines are dependant on the turbo to make horsepower, so no. They do not become like an n/a plane without it - full power is around 41" mp. The waste gate cable is a critical maintenance item that should be inspected every 50 hours and replaced every other annual.

The turbo normalized engines go back to being n/a if the turbo fails. Will lose some hp at altitude, of course, but go back to the factory numbers/ performance.


I do expect that you will always point out the advantages of the hot shot, BUT

Replaced every 2 years?

That cable is $1,200 dollars or so. Mine is 13 years and just fine.

The key is to never lubricate them. The lubricant will coke up and bind the cable.
 
Re: The Unexpected Drop of MP at 12K Ft

Yes. They squeeze an extra 10 hp out of them by lowering the compression to prevent predetonation and increasing the boost. So, without the turbo spinning they don't have enough compression to make power.

How much can they make without the turbo - I don't know? 100hp? 120? I don't know?


Yes the compression ratio is lower on the TO360 7.3 to 1 vs the straight 360's compression ratio of 8.5 to 1 but that is not the issue.


The wastegate is responsible for proportioning how much of the exhaust gas is going to the turbo and how much is just going down the tailpipe. This proportioning directly effects how fast the turbo is turning and hence Manifold pressure.

In a failure such as this the wastgate defaults to open which sends most of the exhaust gas down the tailpipe. The loss of a portion of the exhaust gas to the turbo, and the reduction in rpm's of the turbo is what accounts for the power loss.


Flying clean, 20" will get you to an airport - not fast but it should get you there.


Inspection of the wastegate, turbo, cable and rod ends should be regularly done. I do so at each oil change (takes a few minutes.)
 
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Re: The Unexpected Drop of MP at 12K Ft

Thanks for sharing Alex and glad you're OK. Let us know what else you might find out about what caused that wastegate cable to break.

This is what we know so far.

When we overhauled the engine, 118 hours ago, the old wastegate cable was removed and sent to Beechhurst. They went by the old cable to manufacture the new one but yesterday I found out that the old one was incorrect as it was 8 inches longer. So the previous owner had installed an incorrect cable and Beechhurt recreated it thinking the TCA was different than the TC. They show my cable as the only one of its type they had ever made but they show they made 19 others for TCs of the correct length. Although they agreed to send a new one, of the correct length, at no cost, I am replacing it with the Lycoming cable and keeping theirs as a spare in the back of the plane.

The reality is that we still do not know what caused the failure, as we have not removed the old cable yet since we are waiting for the parts and the plane is still in Tallahassee. Once removed it will be sent back to them for review. I will share the findings as soon as I know.
 
Re: The Unexpected Drop of MP at 12K Ft

Thank you for sharing, Alex.

For those symptoms - I would have guessed turbo charger failure.
Wastegate cable - similar results.

Good emergency handling. Good write-up. Glad it worked out.
Its always good to have a calm right seater.

I can't imagine this scenario with a panic on the right seat. Its a good wife conversation to have in the comfort of one's home to get them in the mind set for when an emergency happens. I am glad we had it at a while back and she followed through.
 
Re: The Unexpected Drop of MP at 12K Ft

Great job Alex. Good reminder to practice glide scenarios....

We fight these wastegate cables all the time. Did it break at the rod end or the cable itself? Did you notice it working stiffer than usual in the flights preceeding this one? I know you did a complete overhaul after you bought the airplane. Did they refurb the cable?

Sure would be helpful to us if you got a pic showing the break location before they remove the cable from the airplene.

They don't fly well at 20" do they? k

I treated it as a glide and never found out. This is my guess. Extending the glide - yes, hold a lower altitude - maybe, climb - who knows. When I was in the clouds trying to hold Va, it was swinging the airspeed between 80 and 100 and I was still descending.
 
Re: The Unexpected Drop of MP at 12K Ft

This is what we know so far.

When we overhauled the engine, 118 hours ago, the old wastegate cable was removed and sent to Beechhurst. They went by the old cable to manufacture the new one but yesterday I found out that the old one was incorrect as it was 8 inches longer. So the previous owner had installed an incorrect cable and Beechhurt recreated it thinking the TCA was different than the TC. They show my cable as the only one of its type they had ever made but they show they made 19 others for TCs of the correct length. Although they agreed to send a new one, of the correct length, at no cost, I am replacing it with the Lycoming cable and keeping theirs as a spare in the back of the plane.

The reality is that we still do not know what caused the failure, as we have not removed the old cable yet since we are waiting for the parts and the plane is still in Tallahassee. Once removed it will be sent back to them for review. I will share the findings as soon as I know.
8"?? Damn... I am surprised it even fit that way. That is a bunch of extra
 
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