Browse: Departments Dates Agencies
Docket ID: [Docket No. FAA-2008-0442, Directorate Identifier 2007-SW-24-AD]
RIN ID: RIN 2120-AA64
SUBJECT CATEGORY: Airworthiness Directives; Sikorsky Aircraft Corporation Model S- 61A, D, E, L, N, NM, R, and V; Croman Corporation Model SH-3H, Carson Helicopters, Inc. Model S-61L; Glacier Helicopter Model CH-3E; Robinson AirCrane, Inc. Model CH-3E, CH-3C, HH-3C and HH-3E; and Siller Helicopters Model CH-3E and SH-3A Helicopters
DOCUMENT SUMMARY: This amendment proposes superseding an existing airworthiness directive (AD) for Sikorsky Aircraft Corporation (Sikorsky) Model S 61A, D, E, L, N, NM, R, and V helicopters. The existing AD currently requires determining whether the main rotor shaft (MRS) was used in repetitive external lift (REL) operations. The existing AD also requires a nondestructive inspection (NDI) for cracks, replacing any unairworthy MRS with an airworthy MRS, appropriately marking the MRS, making a logbook entry, and establishing retirement lives for each REL MRS. This proposed AD would contain some of the same requirements but would determine new retirement lives for each MRS. The REL retirement life would be based on hours timeinservice (TIS) or lift cycles, whichever occurs first. The NonREL retirement life would be reduced and would only be based on hours TIS. This proposed AD would also require the operator to remove from service any MRS with oversized dowel pin bores. Also, certain restricted category models that were inadvertently omitted in the current AD would be added to the applicability. This proposed AD is prompted by the manufacturer's reevaluation of the retirement life for the MRS based on torque, groundairground (GAG) cycle, and fatigue testing. The actions specified by the proposed AD are intended to prevent MRS structural failure, loss of power to the main rotor, and subsequent loss of control of the helicopter.
SUMMARY: Sikorsky Aircraft Corp. Model S-61A, D, E, L, N, NM, R, and V; Croman Corp. Model SH-3H, Carson Helicopters, Inc. Model S-61L; Glacier Helicopter Model CH-3,
We invite you to submit any written data, views, or arguments regarding this proposed AD. Send your comments to the address listed under the caption ADDRESSES. Include the docket number ``FAA20080442, Directorate Identifier 2007SW24AD'' at the beginning of your comments. We specifically invite comments on the overall regulatory, economic, environmental, and energy aspects of the proposed AD. We will consider all comments received by the closing date and may amend the proposed AD in light of those comments.
We will post all comments we receive, without change, to http:// www.regulations.gov, including any personal information you provide. We will also post a report summarizing each substantive verbal contact with FAA personnel concerning this proposed rulemaking. Using the search function of the docket Web site, you can find and read the comments to any of our dockets, including the name of the individual who sent or signed the comment. You may review the DOT's complete Privacy Act Statement in the Federal Register published on April 11, 2000 (65 FR 1947778).
You may examine the docket that contains the proposed AD, any comments, and other information in person at the Docket Operations office between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The Docket Operations office (telephone (800) 6475527) is located in Room W12140 on the ground floor of the West Building at the street address stated in the ADDRESSES section. Comments will be available in the AD docket shortly after receipt.
In 1995 a Model S58T helicopter lost transmission drive due to fatigue cracking on the MRS flange connection. Due to similarities between the Model S58T and the S61 MRS drive connection, Sikorsky conducted a review of the Model S61 MRS cracking history. This review identified similar fatigue cracking mode origins in similar locations in both the Model S61 and the S58T MRS.
On December 7, 1998, the FAA issued AD 982602, Amendment 3910943 (63 FR 69177), Docket No. 96SW29AD, for Sikorsky Model S61A, D, E, L, N, NM, R, and V helicopters. AD 982602 requires an NDI for cracks, replacing any unairworthy MRS with an airworthy MRS, appropriately marking the MRS by following Sikorsky Alert Service Bulletin (ASB) 61B3568, dated July 19, 1996, and making logbook entries. AD 982602 also establishes retirement lives of 1,500 hours TIS for unmodified MRS assemblies used in REL operations and 2,200 hours TIS for modified MRS assemblies used in REL operations. That action was prompted by four reports of cracks in helicopter MRSs used in REL operations. That condition, if not corrected, could result in MRS structural failure, loss of power to the main rotor, and subsequent loss of control of the helicopter.
Since issuing AD 982602, an investigation of REL operations revealed the REL mission profile parameters have changed significantly from those previously used to calculate the MRS retirement lives. The original MRS was certified by analysis in shaft bending only. Due to the service history, Sikorsky performed fatigue testing with Torque GAG cycles for both REL and NonREL spectrums. The results of the fatigue testing with torque GAG cycles prompted changes in certain life limits. This information has led to the need for new retirement criteria for MRSs used in both REL and nonREL operations.
Sikorsky has issued Customer Service Notice (CSN) No. 613510A and Sikorsky Service Bulletin (SB) No. 61B3553A, both dated April 19, 2004. The CSN and the SB apply to Model S61L, N, and NM (serial number (S/N) 61454), and R series transport category helicopters; and S61A, D, E, and V series restricted category helicopters. The CSN specifies replacing the planetary assembly and MRS assembly attaching hardware with high strength hardware. The CSN also specifies reworking the dowel retainer to increase hole chamfer and related countersink diameters. The SB specifies replacing the existing planetary matching plates with new steel matching plates during overhaul at the operator's discretion.
Also, Sikorsky has issued ASB No. 61B3569, dated April 19, 2004 (ASB 61B3569), which supersedes ASB 61B3568B. ASB 61B3569 provides updated procedures for determining REL and NonREL status, assigns new REL and NonREL MRS retirement lives, and provides a method for marking the REL MRS.
We have identified an unsafe condition that is likely to exist or
develop on other Sikorsky model helicopters of these same type designs.
Therefore, the proposed AD would supersede AD 982602 to require the following:
We estimate that this proposed AD would affect 60 helicopters of U.S. registry, and the NDI inspection, remarking, and replacing an MRS would take about 2.2 work hours per helicopter at an average labor rate of $80 per work hour. Required parts would cost about $50 for the supplies required for the NDI inspection and $47,438 for each MRS per helicopter. Based on these figures, we estimate the total cost impact of the proposed AD on U.S. operators to be $2,859,840, assuming, after an NDI, one MRS would be replaced on each helicopter in the fleet because of the revised life, cracks, or oversized dowel pin bores and the recordkeeping cost would be negligible.
We have determined that this proposed AD would not have federalism implications under Executive Order 13132. Additionally, this proposed AD would 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.
For the reasons discussed above, I certify that the proposed regulation:
1. Is not a ``significant regulatory action'' under Executive Order 12866;
2. Is not a ``significant rule'' under the DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); and
3. Will not have a significant economic impact, positive or negative, on a substantial number of small entities under the criteria of the Regulatory Flexibility Act.
We prepared a draft economic evaluation of the estimated costs to comply with this proposed AD. See the AD docket to examine the draft economic evaluation.
Title 49 of the United States Code specifies the FAA's authority to issue rules on aviation safety. Subtitle I,
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Section 106, describes the authority of the FAA Administrator. Subtitle
VII, Aviation Programs, describes in more detail the scope of the Agency's authority.
We are issuing this rulemaking under the authority described in Subtitle VII, Part A, Subpart III, Section 44701, ``General requirements.'' Under that section, Congress charges the FAA with promoting safe flight of civil aircraft in air commerce by prescribing regulations for practices, methods, and procedures the Administrator finds necessary for safety in air commerce. This regulation is within the scope of that authority because it addresses an unsafe condition that is likely to exist or develop on products identified in this rulemaking action.
Air transportation, Aircraft, Aviation safety, Safety. The Proposed Amendment
Accordingly, pursuant to the authority delegated to me by the Administrator, the Federal Aviation Administration proposes to amend part 39 of the Federal Aviation Regulations (14 CFR part 39) as follows:
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
2. Section 39.13 is amended by removing Amendment 3910943 (63 FR
69177, December 16, 1998), and by adding a new airworthiness directive (AD), to read as follows:
Sikorsky Aircraft Corporation; Croman Corporation; Carson
Helicopters, Inc.; Glacier Helicopter; Robinson Aircrane, Inc.; and
Siller Helicopters: Docket No. FAA20080442. Directorate Identifier
2007SW24AD. Supersedes AD 982602, Amendment 3910943, Docket No. 96SW29AD.
Model S61A, D, E, L, N, NM (serial number (S/N) 61454), R, V,
CH3C, CH3E, HH3C, HH3E, SH3A, and SH3H helicopters with main
rotor shaft (MRS), part number (P/N) S613520640001, S613520640
002, or S613723040001, installed, certificated in any category. Compliance
Required as indicated.
To prevent MRS structural failure, loss of power to the main
rotor, and subsequent loss of control of the helicopter, do the following:
(a) Within 10 hours timeinservice (TIS), unless done
previously:
(1) Create a component history card or equivalent record for each MRS.
(2) Count and, at the end of each days operations, record the
number of external lift cycles (lift cycles) performed and the hours
TIS. An external lift cycle is defined as a flight cycle in which an
external load is picked up, the helicopter is repositioned (through
flight or hover), and the helicopter hovers and releases the load and departs or lands and departs.
(3) If you do not have records of the hours TIS on an individual MRS, substitute the helicopter's hours TIS.
(b) Determine whether the MRS is a repetitive external lift
(REL) or NonREL MRS operation by using a 250hour TIS moving average.
(1) Upon reaching 250 hours TIS, calculate the first moving
average of lift cycles by following the instructions in Section I of Appendix I of this AD.
(i) If the calculation results in more than 6 lift cycles per hour TIS, the MRS is an REL MRS.
(ii) If the calculation results in 6 or less lift cycles per hour TIS, the MRS is a NonREL MRS.
(iii) If you know only a portion of the number of the lift
cycles during the previous 250 hours TIS, add the known number to a
number calculated by multiplying the number of hours TIS for which
you do not know the lift cycles by a factor of 30 to arrive at the
accumulated number of lift cycles for that interval. Then, calculate
the lift cycles per hour TIS as described in paragraph (b)(1) of this AD.
(2) If you determine the MRS is a NonREL MRS based on the
previous calculation of the 250hour TIS moving average for lift
cycles, thereafter at intervals of 50 hour TIS, recalculate the
average lift cycles per hour TIS. Recalculate the average lift
cycles by following the instructions in Section II of Appendix 1 of this AD.
(i) If the calculation results in more than 6 lift cycles per hour TIS, the MRS is an REL MRS.
(ii) If the calculation results in 6 or less lift cycles per hour TIS, the MRS is a NonREL MRS.
(iii) If you know only a portion of the number of the lift
cycles during the next interval of 50 hours TIS, add the known
number to a number calculated by multiplying the number of hours TIS
for which you do not know the lift cycles by a factor of 30 to
arrive at the accumulated number of lift cycles. Then, calculate the
lift cycles per hour TIS as described in paragraph (b)(2) of this AD.
(3) Once an MRS is determined to be an REL MRS, you no longer
need to perform the 250hour TIS moving average calculation, but you
must continue to count and record the lift cycles and number of hours TIS.
Note 1: Sikorsky Aircraft Corporation issued an All Operators
Letter (AOL) CCS61AOL040005, dated May 18, 2004, with an example
and additional information about tracking cycles and the moving
average procedure. You can obtain this AOL from the manufacturer at the address stated in the ADDRESSES portion of this AD.
(c) Within 5 hours TIS, after determining the MRS is an REL MRS,
identify it as an REL MRS by etching ``REL'' on the outside diameter
of the MRS near the part S/N. Identify the REL MRS by following the
Accomplishment Instructions, paragraph 3.C., of Sikorsky Alert
Service Bulletin 61B3569, dated April 19, 2004 (ASB 61B3569).
(d) If an MRS is determined to be an REL MRS, it remains an REL
MRS for the rest of its service life and is subject to the retirement times for an REL MRS.
(e) For each REL MRS, within 1,100 hours TIS, conduct a non
destructive inspection (NDI) for cracks in the MRS. If a crack is
found in an MRS, replace it with an airworthy MRS before further flight.
(f) Replace each MRS with an airworthy MRS on or before reaching the revised retirement life as follows:
(1) For an REL MRS that is not modified by following Sikorsky
Customer Service Notice 613510, dated March 18, 1987, and Sikorsky
ASB No. 61B3553, dated December 2, 1981 (unmodified REL MRS);
establish a retirement life of 30,000 lift cycles or 1,500 hours
TIS, whichever occurs first. Replace it on or before accumulating
30,000 lift cycles or 1,500 hours TIS, whichever comes first. For an
unmodified REL MRS installed on a helicopter on the effective date
of this AD that has accumulated more than 30,000 lift cycles or
1,350 hours TIS, replace it within 150 hours TIS or upon removal, whichever occurs first.
(2) For an REL MRS that is modified by following Sikorsky
Customer Service Notice 613510, dated March 18, 1987, and Sikorsky
ASB No. 61B3553, dated December 2, 1981 (modified REL MRS);
establish a retirement life of 30,000 lift cycles or 5,000 hours
TIS, whichever occurs first. Replace it on or before accumulating
30,000 lift cycles or 5,000 hours TIS, whichever comes first. For a
modified REL MRS installed on a helicopter on the effective date of
this AD that has accumulated more than 30,000 lift cycles or 4,500
hours TIS, replace it within 500 hours TIS or upon removal, whichever occurs first.
(3) For a NonREL MRS, reduce the retirement life to 13,000
hours TIS. For a NonREL MRS installed on a helicopter on the
effective date of this AD that has accumulated more than 11,500 but
less than 40,500 hours TIS, replace it within 1,500 hours TIS, or upon removal, whichever occurs first. If the
Note: nonREL MRS has accumulated more than 40,500 hours TIS, replace it on or before it reaches 42,000 hours TIS.
(g) This AD establishes or revises the retirement lives of the
MRS as indicated in paragraphs (f)(1) through (f)(3) of this AD.
(h) Record the revised retirement life on the MRS component history card or equivalent record.
(i) Within 50 hours TIS, remove from service any MRS with oversized (0.8860'' or greater diameter) dowel pin bores.
Note 2: The Overhaul and Repair Instruction (ORI) Number 6135
281, Part B, Step 5, or ORI 6137041, Section III, Oversize Dowel
Pin Bore Repair and identified on the flange as TS281 or TS0413, pertains to the subject of this AD.
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(j) To request a different method of compliance or a different
compliance time for this AD, follow the procedures in 14 CFR 39.19.
Contact the Manager, Boston Aircraft Certification Office, FAA,
FOR FURTHER INFORMATION CONTACT Jeffrey Lee, Aviation Safety Engineer, Boston Aircraft Certification Office, 12 New England Executive Park, Burlington, MA 01803, telephone (781) 2387161, fax (781) 2387170.
14 CFR Part 39 40 CFR Part 52 14 CFR Part 71 33 CFR Part 165 50 CFR Part 679 26 CFR Part 1 40 CFR Part 180 47 CFR Part 73 50 CFR Part 17 33 CFR Part 117 44 CFR Part 67 50 CFR Part 648 14 CFR Part 97 33 CFR Part 100 40 CFR Part 63 50 CFR Part 622 26 CFR Part 301 39 CFR Part 111 40 CFR Part 300 50 CFR Part 660 44 CFR Part 65 40 CFR Parts 52 and 81 40 CFR Part 271 47 CFR Part 64 50 CFR Part 665 47 CFR Part 76 50 CFR Part 229 14 CFR Part 23 14 CFR Part 25 21 CFR Part 522