Date: 201401
Local time of day: 0601-1200
Location: ZZZ.TRACON, US
Flight conditions: VMC
Light: Daylight
Aircraft: PA-42 Cheyenne III/IIIA
Operator: Corporate
Operating under: Part 91
Flight plan: IFR
Mission: Passenger
Flight phase: Initial Climb
Airspace: Class E ZZZ
ATC / advisory: TRACON ZZZ
Aircraft component: Powerplant Fuel System
Component problem: Failed
Reporter organization: Corporate
Reporter function: Single Pilot; Pilot Flying
Reporter qualification: Flight Crew Instrument; Flight Crew Flight Instructor; Flight Crew Multiengine; Flight Crew Air Transport Pilot (ATP)
Anomaly: Aircraft Equipment Problem Critical
Detector: Person Flight Crew
When detected: In-flight
Result: Flight Crew Diverted; General Declared Emergency; General Maintenance Action
Contributing factors: Aircraft; Procedure
Primary problem: Aircraft

Narrative: Shortly after takeoff I experienced an inflight engine failure on the right engine. I declared an emergency and diverted to a larger nearby airport due to the patchy snow and ice on the runway from which I had taken off. I had no issue maintaining altitude and airspeed with the aircraft and completed a safe single engine landing. Local FBO Maintenance determined the main pressure fuel line had broken causing the failure. A new fuel line was ordered and installed by Maintenance. After a successful leak check and ground run; Maintenance signed off the aircraft for flight.Two days later I flew the aircraft on a test flight to ensure it had no further issues. I leveled off at 6;000 FT and approximately 5 minutes after level off; the right engine failed again. I declared an emergency and completed a safe single engine landing. It was discovered that the same main pressure fuel line had broken causing the engine failure. A new line was ordered and a thorough inspection by Maintenance was completed to discover the problem. No issue was discovered and the mechanic believed the fuel line we ordered was defective. After the new line was installed we completed another ground leak check and engine run. Everything checked out okay and Maintenance once again signed the plane off for flight.The following day I completed an additional ground run check at a climb power setting on the right engine for approximately 10-15 minutes continuous to ensure there was no issue with the right engine before takeoff. Everything checked out okay and the engine ran normally. I took off with no issues and climbed to my cruising altitude. After about 15 min cruising at FL240; the right engine flamed out again. I completed the engine securing procedures; declared an emergency; and returned to the airport for an emergency landing. All procedures and checklists were complied with along with the engine securing and single engine landing emergency checklists. ARFF was standing by and a safe single engine landing was completed. I was able to taxi to the FBO  on my own power. Upon inspection by the local maintenance facility; the main fuel pressure line had broken causing the inflight engine failure.The aircraft is remaining at the maintenance facililty until the cause of the repeated fuel line breakage shortly after takeoff can be determined and a successful repair made.

Callback: The reporter advised the aircraft remains grounded as no obvious cause of the failures has been determined.  He believed the original replacement line was from another engine but that the third was brand new from the manufacturer; thus precluding possibilities of either uniquely faulty units or long term in service exposure.  The engine; however; was in extended service under an increased TBO program about which he had no details.  He stated that each of the three failed--approximately 10' long--lines broke at an identical location about 1/4' from the downstream end fitting and that there was no evidence of chaffing or foreign impingement from other structures or components.Lastly; he advised that the original failure had occurred on the last of three back to back; anomaly free; legs flown by himself and that the aircraft had recently been utilized on an extended flight into Canada where no faults were encountered.



Synopsis: The pilot of a PA-42 suffered the failure of the right engine shortly after takeoff and diverted to a nearby airport for an emergency landing.  Maintenance determined the pressure fuel line to the engine had failed and replaced it. On a subsequent test flight the identical failure occurred again.  Believing the replacement fuel line may have been faulty the sequence was repeated including yet another identical pressure line failure.  The aircraft was grounded at the maintenance facility pending a diagnosis and successful repair.