[Federal Register Volume 65, Number 240 (Wednesday, December 13, 2000)]
[Rules and Regulations]
[Pages 77785-77811]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 00-31628]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2000-SW-28-AD; Amendment 39-12042; AD 2000-15-52]
RIN 2120-AA64
Airworthiness Directives; Bell Helicopter Textron, Inc. Model
204B, 205A, 205A-1, 205B, and 212 Helicopters
AGENCY: Federal Aviation Administration, DOT.
ACTION: Final rule; request for comments.
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SUMMARY: This document publishes in the Federal Register an amendment
adopting superseding Airworthiness Directive (AD) 2000-15-52, which was
sent previously to all known U.S. owners and operators of Bell
Helicopter Textron, Inc. Model (BHTI) Model 204B, 205A, 205A-1, 205B,
and 212 helicopters by individual letters. This AD reduces the
retirement index number (RIN) life limit for the main rotor mast
(mast); increases the RIN factor for masts and main rotor trunnions
(trunnions); applies standard RIN factors for all external load lifts;
and requires a one-time inspection of the snap ring groove area of the
mast. This AD also establishes RIN factors for masts and trunnions that
have been previously installed on military or restricted category
helicopters and removes from service those masts that have been
previously installed with a hub spring. This amendment is prompted by
an occurrence of a cracked mast at a lower value than the established
RIN life limit. The actions specified by this AD are intended to
preclude the occurrence of fatigue
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cracks in the damper clamp splined area of a mast. A crack in the
damper clamp splined area could result in failure of a mast or
trunnion, separation of the main rotor system, and subsequent loss of
control of the helicopter.
DATES: Effective December 28, 2000, to all persons except those persons
to whom it was made immediately effective by Emergency AD 2000-15-52,
issued on July 25, 2000, which contained the requirements of this
amendment.
Comments for inclusion in the Rules Docket must be received on or
before February 12, 2001.
ADDRESSES: Submit comments in triplicate to the Federal Aviation
Administration (FAA), Office of the Regional Counsel, Southwest Region,
Attention: Rules Docket No. 2000-SW-28-AD, 2601 Meacham Blvd., Room
663, Fort Worth, Texas 76137. You may also send comments electronically
to the Rules Docket at the following address: [email protected].
FOR FURTHER INFORMATION CONTACT: Michael Kohner, Aviation Safety
Engineer, FAA, Rotorcraft Directorate, Rotorcraft Certification Office,
Fort Worth, Texas 76193-0170, telephone (817) 222-5447, fax (817) 222-
5783.
SUPPLEMENTARY INFORMATION: On November 13, 1998, the FAA issued AD 98-
24-15 (Amendment 39-10900 (63 FR 64612, November 23, 1998), Docket No.
97-SW-20-AD. That AD required establishing a RIN tracking system for
mast and trunnion torque events; creating component history cards or
equivalent records; converting accumulated factored flight hours to a
baseline accumulated RIN count; establishing a system for tracking
increases to the accumulated RIN; and establishing a maximum
accumulated RIN for certain masts and trunnions. That action was
prompted by an accident involving a BHTI Model 205A-1 helicopter in
which a mast failure caused a separation of the main rotor from the
helicopter. A subsequent metallurgical examination revealed that the
mast had fractured as a result of fatigue. Analyses and fatigue testing
conducted by the manufacturer and assessed by the FAA confirmed that
the remaining lives of the mast and trunnion are more accurately
assessed by monitoring the number of torque events and flight hours on
the helicopter rather than by monitoring only flight hours.
The FAA superseded AD 98-24-15 by issuing Emergency AD 2000-08-52
(Docket No. 2000-SW-20) on April 21, 2000. AD 2000-08-52 required a
one-time special inspection for certain serial-numbered masts to detect
burrs or inadequate radii in the snap ring groove areas that can cause
fatigue failure. That AD was issued as a result of an accident
involving a BHTI Model 212 helicopter following in-flight separation of
its main rotor system. The post-accident investigation revealed a
fatigue failure in the damper clamp splined area of the mast, part
number (P/N) 204-011-450-007. Also, operators reported at least five
other failures in the damper clamp splined area of masts, P/N 204-011-
450-001, -007, and -105, in either the upper or lower snap ring
grooves. That AD also reduced the maximum allowable RIN life for each
affected mast and changed the RIN counting procedure to require
application of a standard RIN factor for all external load lifts
regardless of altitude change and the type of load lifted. The RIN
factor assessed for each torque event was increased for masts installed
on BHTI Model 204B and 205B helicopters. The requirements of AD 98-24-
15 pertaining to trunnions, P/N 204-011-105-001 and -103, were not
changed by AD 2000-08-52.
After issuing AD 2000-08-52, the FAA received a report of another
cracked mast. Metallurgical inspection revealed that the mast cracked
as a result of fatigue in snap ring groove radii that were smaller than
the 0.020 inch minimum allowable dimension. Detailed takeoff (1,249)
and lift (16,339) event data for the entire life of the mast confirmed
that the accumulated RIN count at the time the fatigue crack was
detected was approximately 68,000 when calculated in accordance with
the most recent RIN counting procedure as defined in AD 2000-08-52. The
FAA concluded that several corrections to the RIN counting procedure
are required based on a review of the fatigue data and previously
issued AD's.
On July 25, 2000, the FAA issued Emergency AD 2000-15-52 for BHTI
Model 204B, 205A, 205A-1, 205B, and 212 helicopters. That Emergency AD
reduces the RIN life limit for the mast and trunnion; increases the RIN
factor for the masts and trunnions; applies standard RIN factors for
all external load lifts; and requires a one-time inspection of the snap
ring groove area of the mast. That Emergency AD also establishes RIN
factors for masts and trunnions that have been previously installed on
military or restricted category helicopters and removes from service
those masts that have been previously installed with a hub spring. That
action was prompted by an occurrence of a cracked mast at a lower value
than the established RIN life limit. This condition, if not corrected,
could result in failure of a mast or trunnion, separation of the main
rotor system, and subsequent loss of control of the helicopter.
Since the unsafe condition described is likely to exist or develop
on other BHTI Model 204B, 205A, 205A-1, 205B, and 212 helicopters of
the same type designs, the FAA issued Emergency AD 2000-15-52 to
prevent failure of a mast or trunnion, separation of the main rotor
system, and subsequent loss of control of the helicopter. The AD
retains the following requirements from previously issued AD 2000-08-
52:
Reduces the allowable RIN life limit established in AD 98-
24-15 for masts, P/N 204-011-450-001, -007, -105, -113, and -119;
Increases the RIN factor assessed for each torque event
for BHTI Model 204B and 205B helicopters;
Applies a standard RIN factor for all external load lifts
regardless of altitude change and type of load lifted; and
Requires a one-time special inspection of certain S/N
masts for inadequate radii and presence of burrs in the snap ring
groove areas.
The Emergency AD differs from AD 2000-08-52 in that it:
Requires, before further flight, that the accumulated RIN
for all mast and trunnion history prior to the implementation of RIN
counting (required by AD 98-24-15) be corrected for inadequate factors
used to calculate factored hours TIS and to convert factored flight
hours to accumulated RIN;
Increases the RIN factor for each takeoff and external
load lift for masts and trunnions installed on BHTI Model 204B, 205A,
and 205A-1 helicopters to properly reflect the actual level of torque
(horsepower rating) applied to the mast when it is installed in these
helicopter models;
Expands the requirement for a one-time special inspection
to detect inadequate radii and burrs in the snap ring grooves to
include masts with S/N's 00000 through 52720, 61433 through 61444, and
61457 through 61465, regardless of prefix;
Establishes RIN factors for masts and trunnions that have
been previously installed on military helicopters (BHTI-manufactured
Model HH-1K, TH-1F, TH-1L, UH-1A, UH-1B, UH-1C, UH-1D, UH-1E, UH-1F,
UH-1G, UH-1H, UH-1L, UH-1M, UH-1N, and UH-1P; and Southwest Florida
Aviation SW204, SW204HP, SW205, and SW205A-1) and restricted category
helicopters (Firefly Aviation Helicopter Services (previously Erickson
Air Crane Co.); Garlick Helicopters, Inc.; Hawkins and Powers Aviation,
Inc.; International
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Helicopters, Inc.; Tamarack Helicopters, Inc. (previously Ranger
Helicopter Services, Inc.); Robinson Air Crane, Inc.; Williams
Helicopter Corporation (previously Scott Paper Co.); Smith Helicopters;
Southern Helicopter, Inc.; Southwest Florida Aviation; Utah State
University; Western International Aviation, Inc.; and U.S. Helicopter,
Inc.).
Requires the immediate removal from service of any mast
that has been previously installed with a hub spring.
The short compliance time involved is required because the
previously described critical unsafe condition can adversely affect the
structural integrity and controllability of the helicopter. Therefore,
the actions previously stated are required at the specified time
intervals, and this AD must be issued immediately.
Since it was found that immediate corrective action was required,
notice and opportunity for prior public comment thereon were
impracticable and contrary to the public interest, and good cause
existed to make the AD effective immediately by individual letters
issued on July 25, 2000 to all known U.S. owners and operators of BHTI
Model 204B, 205A, 205A-1, 205B, and 212 helicopters. These conditions
still exist, and the AD is hereby published in the Federal Register as
an amendment to section 39.13 of the Federal Aviation Regulations (14
CFR 39.13) to make it effective to all persons.
The FAA estimates that 147 helicopters of U.S. registry will be
affected by this AD. It will take approximately 10 work hours per
helicopter to remove and replace the mast, if necessary; 10 work hours
to remove and replace the trunnion, if necessary; and 6 work hours to
inspect the mast for proper radius or a burr. The approximate time
necessary for calculating the accumulated RIN, revising the
Airworthiness Limitations section of the maintenance manuals, and
providing the information requested to the FAA is 15 work hours per
helicopter. The average labor rate is $60 per work hour. Required parts
will cost approximately $9,538 to replace a mast, if necessary, and
$5,300 to replace a trunnion, if necessary. Based on these figures, the
total cost impact of the AD on U.S. operators is estimated to be
$1,675,506 ($11,398 per helicopter, assuming one inspection, one mast
replacement, not trunnion replacement, and that the helicopter's
accumulated RIN is calculated, the maintenance manuals are revised, and
the requested information is submitted to the FAA).
Comments Invited
Although this action is in the form of a final rule that involves
requirements affecting flight safety and, thus, was not preceded by
notice and an opportunity for public comment, comments are invited on
this rule. Interested persons are invited to comment on this rule by
submitting such written data, views, or arguments as they may desire.
Communications should identify the Rules Docket number and be submitted
in triplicate to the address specified under the caption ADDRESSES. All
communications received on or before the closing date for comments will
be considered, and this rule may be amended in light of the comments
received. Factual information that supports the commenter's ideas and
suggestions is extremely helpful in evaluating the effectiveness of the
AD action and determining whether additional rulemaking action would be
needed.
Comments are specifically invited on the overall regulatory,
economic, environmental, and energy aspects of the rule that might
suggest a need to modify the rule. All comments submitted will be
available, both before and after the closing date for comments, in the
Rules Docket for examination by interested persons. A report that
summarizes each FAA-public contact concerned with the substance of this
AD will be filed in the Rules Docket.
Commenters wishing the FAA to acknowledge receipt of their mailed
comments submitted in response to this rule must submit a self-
addressed, stamped postcard on which the following statement is made:
``Comments to Docket No. 2000-SW-28-AD.'' The postcard will be date
stamped and returned to the commenter.
The regulations adopted herein will not have a substantial direct
effect on the States, on the relationship between the national
Government and the States, or on the distribution of power and
responsibilities among the various levels of government. Therefore, it
is determined that this final rule does not have federalism
implications under Executive Order 13132.
The FAA has determined that this regulation is an emergency
regulation that must be issued immediately to correct an unsafe
condition in aircraft, and that it is not a ``significant regulatory
action'' under Executive Order 12866. It has been determined further
that this action involves an emergency regulation under DOT Regulatory
Policies and Procedures (44 FR 11034, February 26, 1979). If it is
determined that this emergency regulation otherwise would be
significant under DOT Regulatory Policies and Procedures, a final
regulatory evaluation will be prepared and placed in the Rules Docket.
A copy of it, if filed, may be obtained from the Rules Docket at the
location provided under the caption ADDRESSES.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Safety.
Adoption of the Amendment
Accordingly, pursuant to the authority delegated to me by the
Administrator, the Federal Aviation Administration amends part 39 of
the Federal Aviation Regulations (14 CFR part 39) as follows:
PART 39--AIRWORTHINESS DIRECTIVES
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
2. Section 39.13 is amended by removing Amendment 39-10900 (63 FR
64612, November 23, 1998) and by adding a new airworthiness directive
to read as follows:
2000-15-52 Bell Helicopter Textron Inc.: Amendment 39-12042. Docket
No. 2000-SW-28-AD. Supersedes Emergency AD 2000-08-52, Docket No.
2000-SW-20-AD, and AD 98-24-15, Amendment 39-10900, Docket No. 97-
SW-20-AD.
Applicability: Model 204B, 205A, 205A-1, 205B, and 212
helicopters, with main rotor mast (mast), part number (P/N) 204-011-
450-001, -007, -105, -113, or -119, or main rotor trunnion
(trunnion), P/N 204-011-105-001 or -103, installed, certificated in
any category.
Note 1: This AD applies to each helicopter identified in the
preceding applicability provision, regardless of whether it has been
otherwise modified, altered, or repaired in the area subject to the
requirements of this AD. For helicopters that have been modified,
altered, or repaired so that the performance of the requirements of
this AD is affected, the owner/operator must request approval for an
alternative method of compliance in accordance with paragraph (i) of
this AD. The request should include an assessment of the effect of
the modification, alteration, or repair on the unsafe condition
addressed by this AD; and if the unsafe condition has not been
eliminated, the request should include specific proposed actions to
address it.
Compliance
Required as indicated, unless accomplished previously.
Note 2: This AD has new requirements which must be complied with
even if AD's
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98-24-15 and 2000-08-52 have already been accomplished. This AD
requires the recalculation of accumulated mast and trunnion RIN and
increases the RIN factors for masts and trunnions installed on
certain helicopter models. This AD also expands the S/N
applicability for the one-time special inspection of the mast.
To prevent failure of a mast or trunnion, separation of the main
rotor system, and subsequent loss of control of the helicopter,
accomplish the following:
(a) Before further flight, determine the accumulated Retirement
Index Number (RIN) in accordance with the Instructions in Appendix 1
of this AD for the mast and Appendix 2 of this AD for the trunnion.
If the helicopter model installation history or hours time-in-
service (TIS) of the mast or trunnion is unknown, remove the mast or
trunnion from service and replace it with an airworthy mast or
trunnion. If the mast has been installed on certain military
helicopters (BHTI-manufactured Model HH-1K, TH-1F, TH-1L, UH-1A, UH-
1B, UH-1C, UH-1D, UH-1E, UH-1F, UH-1G, UH-1H, UH-1L, UH-1M, UH-1N,
and UH-1P; and Southwest Florida Aviation SW204, SW204HP, SW205, or
SW205A-1) or restricted category helicopters (Firefly Aviation
Helicopter Services (previously Erickson Air Crane Co.); Garlick
Helicopters, Inc.; Hawkins and Powers Aviation, Inc.; International
Helicopters, Inc.; Tamarack Helicopters, Inc. (previously Ranger
Helicopter Services, Inc.); Robinson Air Crane, Inc.; Williams
Helicopter Corporation (previously Scott Paper Co.); Smith
Helicopters; Southern Helicopter, Inc.; Southwest Florida Aviation;
Utah State University; Western International Aviation, Inc.; and
U.S. Helicopter, Inc.) and you cannot verify that hub springs have
not been installed, remove the mast from service and replace it with
an airworthy mast.
(b) Before further flight, replace any mast, P/N 204-011-450-113
or 119, that has accumulated 240,000 or more RIN with an airworthy
mast. Before further flight, replace any mast, P/N 204-011-450-001,
-007, or -105, that has accumulated 265,000 or more RIN with an
airworthy mast.
(c) Before further flight, replace any trunnion, P/N 204-011-
105-103, that has accumulated 240,000 or more RIN with an airworthy
trunnion. Before further flight, replace any trunnion, P/N 204-011-
105-001, that has accumulated 265,000 or more RIN with an airworthy
trunnion.
(d) Before reaching 100,000 RIN, inspect the upper and lower
snap ring grooves in the damper clamp splined area of any mast with
serial number (S/N) 00000 through 52720, S/N 61433 through 61444,
and S/N 61457 through S/N 61465 (regardless of prefix) for:
(1) A minimum radius of 0.020 inches around the entire
circumference (see Figures 1 through 3), using a 100x or higher
magnification. If any snap ring groove radius is less than 0.020
inches, replace the mast with an airworthy mast prior to exceeding
100,000 RIN.
(2) A burr, using a 200x or higher magnification. If a burr is
found in any snap ring groove/spline intersection, replace the mast
with an airworthy mast prior to exceeding 170,000 RIN.
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(e) Continue to calculate the accumulated RIN for the mast by
multiplying all takeoff and external load lifts by the RIN factors
defined in columns (D) and (G) of Table 1 of Appendix 1 of this AD.
(f) Continue to calculate the accumulated RIN for the trunnion
by multiplying all takeoff and external load lifts by the RIN
factors defined in columns (D) and (G) of Table 1 of Appendix 2 of
this AD.
(g) Before further flight, revise the Airworthiness Limitations
section of the maintenance manuals for the masts and trunnions in
accordance with Figure 4.
Mast and Trunnion Life Limits
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Hours TIS life Hours TIS life
Mast part No. limit RIN life limit Trunnion part No. limit RIN life limit
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204-011-450-001.................................................... 6,000 265,000 204-011-105-001 15,000 265,000
204-011-450-007.................................................... 15,000 265,000 204-011-105-103 13,000 240,000
204-011-450-105.................................................... 15,000 265,000
204-011-450-113.................................................... 13,000 240,000
204-011-450-119.................................................... 13,000 240,000
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(h) Within 10 days after completing the inspections required by
this AD, provide the information contained on the AD inspection
report, sample format, contained in Appendix 3 of this AD and send
it to the Manager, Rotorcraft Certification Office, Federal Aviation
Administration, Fort Worth, Texas, 76193-0170, USA. Reporting
requirements have been approved by the Office of Management and
Budget and assigned OMB control number 2120-0056.
(i) An alternative method of compliance or adjustment of the
compliance time that provides an acceptable level of safety may be
used if approved by the Manager, Rotorcraft Certification Office,
FAA. Operators shall submit their requests through an FAA Principal
Maintenance Inspector, who may concur or comment and then send it to
the Manager, Rotorcraft Certification Office.
Note 3: Information concerning the existence of approved
alternative methods of compliance with this AD, if any, may be
obtained from the Manager, Rotorcraft Certification Office.
(j) Special flight permits may be issued in accordance with
sections 21.197 and 21.199 of the Federal Aviation Regulations (14
CFR
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21.197 and 21.199) to operate the helicopter to a location where the
requirements of this AD can be accomplished.
(k) This amendment becomes effective on December 28, 2000, to
all persons except those persons to whom it was made immediately
effective by Emergency AD 2000-15-52, issued July 25, 2000, which
contained the requirements of this amendment.
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APPENDIX 1
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APPENDIX 2
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Appendix 3--Ad Compliance Inspection Report
P/N 204-011-450-001/-007/-105/-113/-119 Main Rotor Mast
Provide the following information and mail or fax it to:
Manager, Rotorcraft Certification Office, Federal Aviation
Administration, Fort Worth, Texas, 76193-0170, USA Fax: 817-222-5783
Operator Name:
Aircraft Registration No:
Helicopter Model:
Helicopter S/N:
Mast P/N:
Mast S/N:
Mast RIN:
Mast Total TIS:
Inspection Results
Were any radii during inspection of this mast determined to be
less than 0.020 inches? If yes, what was the dimension measured?
Was a burr found in the inspected snap ring grooves?
Were cracks noted during the inspection?
Who performed this inspection?
Provide any other comments?
Issued in Fort Worth, Texas, on December 5, 2000.
Henry A. Armstrong,
Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 00-31628 Filed 12-12-00; 8:45 am]
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