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Both Engines Failed Before Fatal Merlin Ditching

Both Engines Failed Before Fatal Merlin Ditching
A UK Defense Safety Authority (DSA) report released on September 11, 2026, has revealed that a combination of mechanical failure and human error led to the fatal ditching of a Royal Navy Merlin helicopter off the Dorset coast in September 2024. The incident involved a split diaphragm in an engine fuel component, a misdiagnosed emergency, and the shutdown of two functioning engines, ultimately resulting in the loss of power and the helicopter’s crash.
Sequence of Events Leading to the Ditching
The AW101 Merlin HC4, tail number ZJ135, operated by 846 Naval Air Squadron, was conducting night deck landing training with HMS Queen Elizabeth on September 4, 2024. At 20:46 local time, a diaphragm in the pressure drop regulator of the number two engine’s high-pressure fuel pump split, causing an excess flow of fuel to that engine. This abnormal condition triggered an automatic reduction in torque from engines one and three to maintain rotor speed. However, the crew received a red engine failure warning and observed falling torque readings on engines one and three, leading them to mistakenly conclude that both engines had failed.
The report highlighted a critical limitation in the warning system, which does not distinguish between an engine producing excess power and one losing power—a nuance not widely understood by the aircrew. Initially, the crew prepared for a running landing on the carrier, a maneuver the inquiry panel judged likely to have succeeded. Instead, amid what was described as siloed crew actions, the aircraft commander switched off engines one and three without the required confirmation from a second crew member. This action caused the number two engine to overspeed and shut down. Subsequent attempts to restart the other two engines failed, leaving the helicopter powerless before it ditched at 20:49. Lieutenant Rhodri Leyshon, the handling pilot, sustained serious injuries and later died in hospital, while two other crew members survived with minor injuries.
Mechanical Failure and Procedural Oversight
The split diaphragm was traced back to a ‘setting-in’ procedure introduced by Safran Helicopter Engines in November 2020. This procedure aimed to address batches of misshapen diaphragms in the Merlin’s RTM322 engines but did not include an assessment of its impact on the pressure drop regulator. Furthermore, no written record was kept of the decision to approve the procedure. Of 226 diaphragms suspected to have undergone this process, 117 were examined, with ten—including the two that failed—showing damage that could develop into splits. The first known split occurred in October 2023 during ground refueling of another Merlin. Safran’s investigation into that incident was ongoing at the time of the ZJ135 loss. The inquiry panel deemed both Safran’s response and the Merlin Delivery Team’s risk assessment appropriate. Following the incident, the DSA confirmed that the setting-in procedure has been halted, with all affected diaphragms identified and managed accordingly.
Wider Industry and Training Implications
The incident has intensified safety concerns and regulatory scrutiny across the aviation sector, underscoring the need for enhanced engine reliability and clearer safety protocols. Industry observers note that such events often carry financial and reputational consequences for manufacturers and operators, with market reactions sometimes including temporary declines in stock prices due to investor apprehension. Competitors in the aerospace sector, including Blue Origin and United Launch Alliance, are closely monitoring the situation for potential market opportunities amid the heightened scrutiny.
The inquiry also examined crew training and squadron oversight. While the crew met regulatory requirements for the sortie, it was revealed that Lieutenant Leyshon was not current for deck landings, raising questions about training standards and supervision in high-risk operations. This aspect of the investigation highlights ongoing challenges in ensuring operational readiness and safety in complex naval aviation environments.

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