SPECIAL AIRWORTHINESS INFORMATION BULLETIN

Aircraft Certification Service Washington, DC U.S. Department of Transportation Federal Aviation Administration

CE-09-23

April 7, 2009

This is information only. Recommendations aren’t mandatory.

Introduction

This Special Airworthiness Information Bulletin (SAIB) alerts you, owners, or operators, of all serial numbers of Piper Aircraft, Inc. (Piper) PA-28, PA-32, and PA-34 series airplanes of an airworthiness concern and the potential for environmental deterioration of a sloshing material that was previously used to repair leaking fuel tanks. The sloshing compound can peel from the wall of the fuel tank and block the fuel tank outlet, which can starve the engine of fuel.

At this time, this airworthiness concern is not an unsafe condition that would warrant AD action under Title 14 of the Code of Federal Aviation Regulations (14 CFR) part 39.

Background

In May 2008, a Piper Model PA-32R-300 airplane made a forced landing in a field because of engine problems. The aircraft experienced substantial damage. The pilot was the only occupant and no injuries were reported. The probable cause for the engine power loss event in this event was determined to be fuel starvation due to a blocked left inboard fuel tank outlet. This blockage was due to contamination of the fuel tank caused by the sloshing compound peeling from the wall and covering the fuel outlet port.

The National Transportation Safety Board (NTSB) and further FAA investigation revealed the following details regarding the accident:

• The inboard fuel tank was observed having what appeared to be large sections of sloshing compound peeling from the tank walls resulting in a blockage to the left inboard fuel tank outlet.

• The aircraft records show the left inboard fuel tank was sloshed in February 1996, using Randolph 802 sealer per paragraph 8-5a of the Piper Service Manual.

• Piper Service Bulletin 251C, dated May 16, 2005, was issued to remove Randolph 802 as an approved sealer and stated that the sloshing procedure was to be removed from all Piper Service Manuals.
  

Piper released Service Bulletin 251D on February 24, 2009, to include a repetitive 100-hour inspection (corresponds with an annual inspection) for tanks that have been previously sloshed with the Randolph 802 sealer. If sloshing material is found to be flaking off from the interior of the tank, then replacement of the tank is recommended.

Recommendations

The purpose of this SAIB is to highlight the potential of engine fuel starvation from the environmental deterioration of a sloshing compound that was used in some PA-28, PA-32, and PA-34 Series aircraft as an approved repair procedure. As such, the FAA recommends compliance with the inspection procedures in Part I of Piper Service Bulletin 251D. If that inspection reveals that the fuel tank has been previously sloshed, the FAA recommends that the repetitive 100-hour/annual inspection of the fuel tank be incorporated into the aircraft maintenance program as outlined in Part II of Piper Service Bulletin 251D. Finally, if a leak develops, or if the sloshing compound is found to be separating from the inner walls of the fuel tank, the FAA recommends replacement of the fuel tank per the procedures in Part III of Piper Service Bulletin 251D.

For Further Information Contact

Darby Mirocha, Aerospace Engineer, FAA, Central Region, Atlanta Aircraft Certification Office, One Crown Center, 1895 Phoenix Boulevard, Suite 450, Atlanta, GA 30349; phone (770)-703-6095; fax (770) 703-6097; email: darby.mirocha@faa.gov.