What happened
On March 28, 2002, a Piper PA-32R-301T departed Zweibrücken for a private instrument flight to Berlin-Tempelhof. Shortly after reaching cruise altitude, a passenger noticed a burning smell. The pilot subsequently observed smoke and flames emanating from the engine.
Following a Mayday call, the pilot was directed to perform an emergency landing at Ramstein. During the descent, the intense heat caused the aircraft's windshield to melt, allowing smoke and flames to penetrate the cabin. Upon landing on runway 27, the pilot lost control of the aircraft due to severe visibility impairment and heat. The aircraft struck the Visual Approach Slope Indicator (VASIS) components, causing the right wing tank to rupture and ignite. The aircraft came to a halt 55 meters from the runway.
Tragically, the accident resulted in one fatality and one serious injury. While the pilot and one passenger managed to escape, the second passenger died due to smoke inhalation and heat exposure.
The investigation
The BFU examined the wreckage and analyzed engine components, including the turbocharger and heat exchanger. Investigators focused on the heating system, which utilized an air duct to distribute warmed air from the exhaust heat exchanger into the cabin. The investigation also reviewed radio communications between the pilot, Frankfurt Radar, and Ramstein Tower, as well as the response times of the airfield rescue services.
Findings
Investigators determined that the fire originated in the engine compartment, likely caused by an oil leak near the engine mount that ignited upon contact with the turbocharger. The investigation found that the heating control valves for the cabin and windshield de-icing were left in a half-open position. This allowed hot combustion gases to enter the heating ducts and flow into the cockpit.
It was concluded that the melting of the windshield and the subsequent influx of smoke and flames into the cabin—which led to the loss of control—could likely have been prevented if the pilot had closed the heating regulators immediately upon detecting the fire.