CSI AVIATION INC

Operated by CSI AVIATION INC (per NTSB report)

AT FL250 PRESSURE DIFFERENTIAL 6.5 HEARD A POP AND DOOR UNLOCKED LIGHT CAME ON. DOOR LATCH BOLT BROKE AND MAIN DOOR WOULDN'T OPEN. MX FOUND FAILURE OF THE UPPER FWD BAYONET (BOLT) 51.5 HRS/42 CYCLES AFTER REPLACEMENT. NO OTHER DAMAGE FOUND. THE KIT USED WAS PN 101-4084-1 SN 1667.

AT FLIGHT LEVEL 27,000 CABIN PRESSURE 6.1. EXPERIENCED RAPID CABIN DEPRESSURIZATION. MX FOUND FAILURE OF THE UPPER AFT BAYONET (BOLT) 23.2HRS AFTER REPLACEMENT. THE AIRCRAFT HAD A RAPID DE-PRESSURIZATION, CABIN MASKS DEPLOYED AND LANDED WITH NO ISSUES. THE DAMAGE NOTED INCLUDES THE SUPPORT CHANNEL WHERE THE BAYONET GUIDE ROLLER SUPPORT IS MOUNTED AND SHEARED RIVETS ON THE FWD LATCH HOOK SUPPORT BRACKET. NO DAMAGE WAS NOTED TO THE AIRFRAME SIDE OF THE DOOR AREA, BAYONET GUIDE OR THE CONTROL ROD THE BAYONET IS SCREWED INTO. THE KIT USED WAS PN 101-4084-1 SN 1619.

DURING WING BOLT INSPECTION, FOUND RH OUTBD LOWER WING BOLT OUTBD FITTING HAS WASHER IMPRESSION. REPAIRED IN ACCORDANCE WITH TEXTRON FIELD REPAIR FR-LJ-1397-15621.

WHILE PERFORMING THE AFT PRESSURE BULKHEAD INSPECTION FOUND A CRACK AT THE # 5 ZEE STIFFENER FROM THE TOP OF THE BULHEAD ON THE FWD SIDE OF THE BULKHEAD THE CRACK STARTS 2.1 INCHES FROM THE OUTBD R/H SIDE AND RUNS HORIZONTALY 21 INCHES JUST UNDER THE RIVET LINE FOR STIFFENER #5. THE #9 STRINGER IS INLINE WITH THE #5 ZEE STIFFENER. REPLACED AFT PRESSURE BULKHEAD LOWER WEB IAW KING AIR SIRM 20-50. INSTALLED Z STIFFENERS PN 101-440119-53/-57 IAW TEXTRON FIELD REPAIR FR-BB-1514-15422 REV -.

BELLY SKIN CRACKED 3/8"AT APPROX FS 181.0 AT STRINGER 16. REPAIRED IAW KING AIR SIRM 20-10-16.

WHILE FLYING AT FL 320 #2 RIGHT SIDE ENGINE LOST OIL PRESSURE INSTANTLY. REQUESTED DIVERT TO KHSV. ON LANDING NOTED OIL DRIPPING FROM BOTTOM OF COWLING. MX FOUND THE OIL COOLERS WELD SEAM SPLIT OPEN (CRACKED). REPLACED OIL COOLER.

BELLY SKIN CRACKED APPROX 3 1/2" ON FRAME AT FS 167.625 BETWEEN STRINGERS 15L AND 16. C/W SKIN DAMAGE REPAIR (PRESSURIZED AREA) COVER PATCH METHOD AND SHIM INSTALLATION IRW BEECHCRAFT SIRM 98-39006, REV D5, 20-10-16, 2. A-D & 20-10-10, 1-4, A.C. FABRICATED .050, 2024-T3 DOUBLER AND .040, 2024-T3 SHIM, COATED DOUBLER AND SHIM WITH BONDERITE M-CR 1201 AERO ALODINE, AND INTEGRAL PRODUCTS SEALANT AC 350 B-1/2 CONFORMING TO AMS-S-8802F, TYII, CL B-1/2. DOUBLER AND SHIM INSTALLED WITH MS20470AD RIVETS IRW SIRM 20-50-02.

FRAME CRACKED AT FS 236.5 BETWEEN STRINGERS 12L AND 13L. REPAIRED IAW KING AIR SIRM 20-10-34.

FRAME CRACKED CENTER LINE ABOVE BELLY SKIN @ APPROXIMATE F.S. 167.625. REPAIRED IAW SIRM 20-10-34.

AFTER TAKE OFF FROM LAS VEGAS, NM, WE HAD A RAPID DECOMPRESSION AT FL260 WITH AIRFLOW HEARD AT THE CABIN DOOR FOLLOWED BY CABIN ALT HI ANNUNCIATOR AND MASTER WARNING. WE DONNED OUR O2 MASKS AND DESCENDED TO 15K' AND DIVERTED TO ABQ. MAINTENANCE FOUND PASSENGER DOOR SEAL DAMAGED. REPLACED DOOR SEAL, OPS CHECK GOOD.

AT 12,000 FT, CLIMBING, WE HEAR A WHISTLE COMING FROM EMERG. EXIT. WHEN WE CLIMBED TO 14,000 FT OUR CABIN ALT WAS 11,000 AND DELTA P WAS AT RECLINE. WE STOPPED CLIMBING AND STARTED DOWN TO 10,000. AFTER FLYING AT 10,000 FOR A SHORT TIME THE MEDICS HEARS A WOOSH OF AIR FROM THE MAIN DOOR AND THE PRESSURE PEGGED AT -7000 AND OURS POPPED HARD. WE DECLARED AN EMERGENCY AND DESCENDED TO 6000 AND WAS UNABLE TO MAINTAIN PRESSURE (-200 -700). FOUND EMERGENCY EXIT DOOR SEAT DE-TATCHED. SECURED DOOR SEAL WITH 1300L IAW KING AIR 90 SERIES MM 52-20-03. FOUND DOOR SEAL INFLATION CONNECTION LEAKED. SECURED CONNECTION AS REQUIRED IAW KING AIR 90 SERIES MM 52-10-13. PERFORMED AIRCRAFT RUN UP. NOTED NO AUDIBLE AIR LEAKS FROM CABIN AND AIRCRAFT PRESSURIZATION OPS CHECK.

AFT PRESSURE BULKHEAD, FWD SIDE HAS CORROSION @ 7 O'CLOCK POSITION WHERE UPHOLSTERY ATTACHES APPROX 1.5" X 1" ALL THE WAY THROUGH METAL. REPAIRED IAW TEXTRON FIELD REPAIR FR-FA-218-12350.

AFT PRESSURE BULKHEAD, FWD SIDE HAS CORROSION @ 10 O'CLOCK POSITION WHERE UPHOLSTERY ATTACHES APPROX 1" X 1.25" 0.008" DEEP. REPAIRED IAW TEXTRON FIELD REPAIR FR-FA-218-12350.

AFT PRESSURE BULKHEAD, FWD SIDE HAS CORROSION @ 12 O'CLOCK LEFT POSITION WHERE UPHOLSTERY ATTACHES APPROX 1" X 1.25" 0.038" DEEP. REPAIRED IAW TEXTRON FIELD REPAIR FR-FA-218-12350.

AFT PRESSURE BULKHEAD, FWD SIDE HAS CORROSION @ 12 O'CLOCK RIGHT POSITION WHERE UPHOLSTERY ATTACHES APPROX 1" X 1.25" 0.028" DEEP. REPAIRED IAW TEXTRON FIELD REPAIR FR-FA-218-12350.

AFT PRESSURE BULKHEAD, FWD SIDE HAS CORROSION @ 2 O'CLOCK POSITION WHERE UPHOLSTERY ATTACHES APPROX 1" X 1.25" ALL THE WAY THROUGH METAL. REPAIRED IAW TEXTRON FIELD REPAIR FR-FA-218-12350.

AFT PRESSURE BULKHEAD FRAME, HAS CORROSION @ APPROX 1 O'CLOCK POSITION LOOKING AFT APPROX 1" X 0.25" FS 347.750. REPAIRED IAW TEXTRON FIELD REPAIR FR-FA-218-12350.

LH AILERON TIP CAP DAMAGE DUE TO COLLISION WITH HANGAR DOOR FRAME. REPAIRED LEFT HAND AILERON, P/N 101-130001-325 S/N BB1755, TIP DAMAGE BY REPLACING TIP PN 101-130001-211 IAW KING AIR SERIES STRUCTURAL INSPECTION AND REPAIR MANUAL (SIRM) 20-50-03. PAINTED NEW AILERON TIP IAW KING AIR SERIES STANDARD PRACTICES MANUAL 20-08-00. BALANCED THE AILERON IAW KING AIR SERIES 200 AMM 57-60-01. REINSTALLED AILERON P/N 101-130001-325 S/N BB1755 ON AIRCRAFT N505AW/SN BB-1755 AND CHECKED FOR PROPER RIGGING/TRAVELS IAW KING AIR SERIES 200 AMM 27-10-05. FUNCTION CHECK GOOD. NO CHANGE TO THE AIRCRAFT'S WEIGHT AND BALANCE. OPERATIONAL CHECK FLIGHT SATISFACTORY.

FRAME CRACKED AT LIGHTNING HOLE AT FS 187.383 JUST ABOVE STRINGER 10R. REPAIRED CRACK FS 187.383 ABOVE STRINGER 10R USING 0.071", 2024-T3 ALCLAD IAW SIRM 20-10-31.

FRAME CRACKED AT FS 256.250 AND STRINGER 13L, PN 50-420068-31. REPAIRED CRACKED FRAME AT FS 256.250 AND STRINGER 13L USING 2024-T3, 0.063" ALCLAD IAW SIRM 20-10-34.

IMPACT DAMAGE NOTED ON RH SIDE FUSELAGE, BELOW AND AFT RH AVIONICS DOOR (PROP ARC). REPAIRED IMPACT DAMAGE TO PRESSURE VESSEL AT FS 94.0, WL 84.0 RH SIDE, AFT OF AVIONICS DOOR IAW BEECHCRAFT SERIES SIRM 20-10-16.

RH FRAME CROSSTIE CRACKED AT APPROX FS 188.0 AND WL 119.0 - RH EMERGENCY EXIT CUT OUT LOWER AFT CORNER. REPAIRED IAW TEXTRON STANDARD REPAIR SR-KA-ATA53-36613

WHILE TAXING/PARKING, RH OUTBD WIND CONTACTED LIGHT POLE. DAMAGE FWD LEADING EDGE INBOARD OF OF WINGLET TO INCLUDE DAMAGE TO RH WING DEICE BOOT.

LH ELEVATOR LIGHTNING STRIKE ON TRAILING EDGE APPROX 1.1" FROM ELEVATOR TRIM TAB AT DRAIN GROMMET. DAMAGE 0.7" X 0.6" THROUGH TOP AND BOTTOM SKIN. REPAIRED IAW TEXTRON REPAIR FR-UE-128-10858

RH STRINGER 9 CRACKED JUST AFT OF AFT PRESSURE BULKHEAD AT APPROX FS 347.750. REPAIRED IN ACCORDANCE WITH TEXTRON KIT 101-4064-4S.

CRACK FOUND DURING ESCAPE HATCH INSPECTION ON RH EMERGENCY EXIT DOOR CROSS TIE, BOTTOM AFT CORNER OF FUSELAGE SIDE AT FS 201.775 ZONE 250, WL 119

RH INBOARD UPPER NACELLE ATTACHMENT HOLE ON TRUSS CRACKED. REPAIRED IAW RAYTHEON AIRCRAFT KING AIR SERIES COMMUNIQUE NO. 62 DATED MAY 1992.

AIRSTAIR DOOR LOWER SKIN CRACKED & DAMAGED AT APPROX FS 288 AT LOWER END WITH DOOR OPEN. REPAIRED IAW TEXTRON FIELD REPAIR FR-FA-98-9257.

AFT SPAR UPPER SPAR CAP CRACKED (FS 327.630) AT LBL 1.0 THRU LBL 5.0. JUST OB OF FLAP MOTOR/GEAR BOX.

STRINGER 9R CRACKED AT LAST RIVET JUST AFT OF AFT PRESSURE BULKHEAD (APPROX FS 557.500)

STRINGER 15R DISBONDED FROM SKIN BETWEEN FS 378.250 AND 393.250.

EMERGENCY EXIT 6A WINDOW PAN CRACKED PART NUMBER 129-430043-3.

EMERGENCY EXIT 4C WINDOW PAN CRACKED PART NUMBER 129-430043-3.

RH #7 STRINGER CRACKED JUST AFT OF AFT PRESSURE BULKHEAD AT APPROX FS 347.75.

RT NR 10 STRINGER CRACKED AT FS 347.75.

BELLY SKIN CRACKED AT FS 288.25 JUST OUTBOARD OF STRINGER 15L APPROXIMATELY 1" AND 1.5". AFTER FURTHER INVESTIGATION, FOUND FRAME SHIM CORRODED. REPAIRED IAW BEECHCRAFT 1900 SRM 51-70-06.

UPON FUSELAGE STRINGER INSPECTION, FOUND LT STRINGER NR 9 AFT OF PRESSURE BULKHEAD APPROXIMATELY FS 347.75 CRACKED, REF WORKCARD 05-20-05 (19)(A).

WRITE UP IN LOGBOOK IS AS FOLLOWS "STRONG EXHAUST/FUEL FUMES PRESENT IN FLIGHT. INITIALLY NOTICED IN REAR CABIN, EVENTUALLY COCKPIT ASSOCIATED WITH FLAP EXTENSION ON FINAL APPROACH" FOR FURTHER INFORMATION, PIC INDICATED THAT MED CREW IN CABIN INITIALLY NOTICED SMELL AND ON FINAL APPROACH FLIGHT CREW NOTICED SMELL. AIRCRAFT LANDED WITH NO ADDITIONAL INCIDENTS. PIC CALLED "ON CALL" MAINTENANCE TO PERFORM GROUND RUN WHILE MOVING BLEEDS AND TEMPERATURE CONTROLS TO DIFFERENT POSITIONS. PIC INDICATED HE COULD NOT DUPLICATE THE SMELL.

WRITE UP IN LOGBOOK IS AS FOLLOWS" WHEN ACFT PRESSURIZED STRONG EXHAUST/FUEL SMELL IN AFT COMPARTMENT(MEANING CABIN FOR CLARIFICATION))FUMES LAST APPROX FIRST 15 OF PRESSURIZATION". FOR FURTHER INFORMATION AFTER TALKING WITH CREW IN THE COCKPIT AREA NO ABNORMAL SMELL NOTED BUT PILOT DECIDED TO FOLLOW SMOKE FUMES AND FLAMES CHECKLIST IN EMERGENCY PROCEDURES DESCENDED AIRCRAFT BELOW 10000FT AND DEPRESSURIZED AIRCRAFT FLEW ONTO BASE AND LANDED WITH NO ADDITIONAL INCIDENTS.

RIGHT BLEED FAIL LIGHT ILLUMINATED IN FLIGHT. POST FLIGHT VISUAL INSPECTION REVEALED A RUPTURED BLEED-AIR-WARNING TUBE LOCATED IN THE RT WING JUST INBD OF THE NACELLE. NO EVIDENCE OF A BLEED AIR LEAK IN THE RT BLEED AIR SUPPLY LINE WAS EVIDENT.