Airworthiness Directives; Hartzell Propeller, Inc., McCauley Propeller Systems, Sensenich Propeller Manufacturing Company, Inc., and Raytheon Aircraft Company Propellers

[Federal Register Volume 68, Number 128 (Thursday, July 3, 2003)]
[Rules and Regulations]
[Pages 39815-39831]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-16689]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2003-NE-13-AD; Amendment 39-13219; AD 2003-13-17]
RIN 2120-AA64


Airworthiness Directives; Hartzell Propeller, Inc., McCauley 
Propeller Systems, Sensenich Propeller Manufacturing Company, Inc., and 
Raytheon Aircraft Company Propellers

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Hartzell Propeller, Inc., McCauley Propeller Systems, Sensenich 
Propeller Manufacturing Company, Inc., and Raytheon Aircraft Company 
(formerly Beech Aircraft Corporation) propellers returned to service by 
T and W Propellers, Inc., of Chino, CA. This AD requires maintenance 
actions amounting to an overhaul of the affected propellers. This AD is 
prompted by the results of a National Transportation Safety Board 
(NTSB) investigation of a failed propeller blade and subsequent 
inspections of various propeller models returned to service by T and W 
Propellers, Inc. We are issuing this AD to detect unsafe conditions 
that could result in separation of a propeller blade and loss of 
control of the airplane.

DATES: Effective July 18, 2003.
    We must receive any comments on this AD by September 2, 2003.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
    [sbull] By mail: The Federal Aviation Administration (FAA), New 
England Region, Office of the Regional Counsel, Attention: Rules Docket 
No. 2003-NE-13-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
    [sbull] By fax: (781) 238-7055.
    [sbull] By e-mail: [email protected].
    You may examine the AD docket at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA.

FOR FURTHER INFORMATION CONTACT: Tomaso DiPaolo, Aerospace Engineer, 
Chicago Aircraft Certification Office, FAA, Small Airplane Directorate, 
2300 East Devon Avenue, Des Plaines, IL 60018-4696; telephone (847) 
294-7031, fax (847) 294-7834.

SUPPLEMENTARY INFORMATION: This AD applies to certain Hartzell 
Propeller, Inc., McCauley Propeller Systems, Sensenich Propeller 
Manufacturing Company, Inc., and Raytheon Aircraft Company (formerly 
Beech Aircraft Corporation) propellers returned to service by T and W 
Propellers, Inc of Chino, CA. This AD requires maintenance actions that 
amount to an overhaul of the affected propellers. This AD is prompted 
by the results of an NTSB investigation into the separation of a 
propeller blade on a Beech 95 Travel Air airplane and subsequent 
inspections of various propeller models returned to service by T and W 
Propellers, Inc. The NTSB metallurgical analysis of the failed blade 
showed that the fracture was approximately 4 inches from the butt end 
of the propeller blade. Several corrosion pits were found in the 
propeller inner blade bearing bore at and around the site of crack 
initiation. While the fatigue failure appeared to have corrosion pits 
as its initiation site, the size of the crack was approximately 4 
inches in the outer surface of the blade shank. A crack of that size is 
visually detectable. However, the time-since-overhaul (TSO) of the 
propeller was reported as being zero hours. Documentation from T and W 
Propellers, Inc. propeller repair station of Chino, CA, indicated that 
they had complied with Hartzell service documents. However, inspection 
of the propellers on the airplane involved showed that T and W 
Propellers, Inc. had not complied with Hartzell service documents. The 
FAA participated in several subsequent teardowns of other propellers 
returned to service by T and W Propellers, Inc. We conducted these 
teardowns on other Hartzell and McCauley propeller models that the 
public provided voluntarily. The cumulative teardown information 
provided enough information to substantiate that T and W Propellers, 
Inc. had introduced unsafe conditions on propellers they had returned 
to service. These inspections uncovered the following unsafe 
conditions:
    [sbull] Extensive corrosion in the internal bearing bore of the 
blade.
    [sbull] Absence of corrosion protection (chemical conversion 
coating and paint) in the internal bearing bore area of the blade.
    [sbull] Cadmium plating on top of deep corrosion pits.
    [sbull] Poor cadmium plating and corrosion in the hub.
    [sbull] Extra phenolic washers that are not approved for use in 
Hartzell propellers.
    [sbull] A deteriorated O-ring that was not replaced during the 
overhaul.
    [sbull] Failure to properly shot peen propeller parts.
We are requiring certain actions in this AD to detect unsafe conditions 
that could result in separation of a propeller blade and loss of 
control of the airplane.

FAA's Determination and Requirements of This AD

    The unsafe condition described previously is likely to exist or 
develop on other propellers that T and W Propellers Inc., propeller 
repair station of Chino, CA, returned to service. We are issuing this 
AD to detect unsafe conditions that could result in separation of a 
propeller blade and loss of control of the airplane. This AD requires 
maintenance actions that amount to an overhaul of certain Hartzell 
Propeller, Inc., McCauley Propeller Systems, Sensenich Propeller 
Manufacturing Company, Inc., and Raytheon Aircraft Company propellers 
returned to service T and W Propellers, Inc., and that are listed by 
serial number (SN) in this AD.

Recommendation for Propellers Not Identified by SN

    This AD currently affects all propellers that we have identified by 
propeller hub SN from 434 T and W Propellers, Inc. shop work order 
records. The records range in date from January 8, 2000 to December 30, 
2002. This range of dates represents a portion of propellers returned 
to service by T and W Propellers, Inc. since January 22, 1997, when the 
FAA issued a repair station certificate to T and W Propellers,

[[Page 39816]]

Inc. The NTSB and the FAA have conducted inspections on propellers 
returned to service by T and W Propellers, Inc. as far back as December 
1997 and found unairworthy conditions similar to those in propellers 
identified by serial number in this AD. The FAA has alerted the public 
of this through Unapproved Parts Notification No. 2003-00142 issued on 
March 31, 2003. The FAA recommends that any propeller not in the 
applicability list for this AD returned to service by T and W 
Propellers, Inc. comply with paragraph (h) of this AD.

FAA's Determination of the Effective Date

    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we have found that notice and opportunity for 
public comment before issuing this amendment is impracticable, and that 
good cause exists for making this amendment effective in less than 30 
days.

Changes to 14 CFR Part 39--Effect on the AD

    On July 10, 2002, we issued a new version of 14 CFR part 39 (67 FR 
47997, July 22, 2002), which governs our AD system. This regulation now 
includes material that relates to special flight permits, alternative 
methods of compliance, and altered products. This material previously 
was included in each individual AD. Since this material is included in 
14 CFR part 39, we will not include it in future AD actions.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment; however, we invite you to submit any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2003-NE-13-AD'' in the 
subject line of your comments. If you want us to acknowledge receipt of 
your mailed comments, send us a self-addressed, stamped postcard with 
the docket number written on it; we will date-stamp your postcard and 
mail it back to you. We specifically invite comments on the overall 
regulatory, economic, environmental, and energy aspects of the rule 
that might suggest a need to modify it. If a person contacts us 
verbally, and that contact relates to a substantive part of this AD, we 
will summarize the contact and place the summary in the docket. We will 
consider all comments received by the closing date and may amend the AD 
in light of those comments.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications with you. You may get more information about plain 
language at http://www.plainlanguage.gov.

Regulatory Findings

    We have determined that this AD will not have federalism 
implications under Executive Order 13132. This AD 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.
    For the reasons discussed above, I certify that the 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 summary of the costs to comply with this AD and 
placed it in the AD Docket. You may get a copy of this summary by 
sending a request to us at the address listed under ADDRESSES. Include 
``AD Docket No. 2003-NE-13-AD'' in your request.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

0
Accordingly, under 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

0
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]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

2003-13-17 Hartzell Propeller, Inc., McCauley Propeller Systems, 
Sensenich Propeller Manufacturing Company, Inc., and Raytheon 
Aircraft Company Propellers: Amendment 39-13219. Docket No. 2003-NE-
13-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective July 18, 
2003.

Affected ADs

    (b) None.
    Applicability: (c) This AD applies to Hartzell Propeller, Inc., 
McCauley Propeller Systems, Sensenich Propeller Manufacturing 
Company, Inc., and Raytheon Aircraft Company (formerly Beech 
Aircraft Corporation) propellers returned to service by T and W 
Propellers, Inc. of Chino, CA, and that have a propeller hub serial 
number (SN) listed in Table 1 of this AD. Table 1 follows:
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Unsafe Condition

    (d) This AD is prompted by the results of a National 
Transportation Safety Board (NTSB) investigation of a failed 
propeller blade and subsequent inspections of various propeller 
models returned to service by T and W Propellers, Inc. We are 
issuing this AD to detect unsafe conditions that could result in 
separation of a propeller blade and loss of control of the airplane.
    Compliance: (e) If you have not already performed the actions 
required by this AD, you must perform the actions within the 
compliance times specified in this AD.

Required Actions

    (f) For propellers listed in Table 1 of this AD, that have been 
overhauled since being returned to service by T and W Propellers, 
Inc by an authorized repair station other than T and W Propellers, 
Inc., no further action is required.

Propellers With Fewer Than 10 Hours Time-in-Service (TIS) Since Return 
to Service

    (g) Before further flight, perform the actions specified in 
paragraph (h) of this AD on propellers listed in Table 1 of this AD, 
that have fewer than 10 hours time-in-service (TIS) since return to 
service by T and W Propellers, Inc. You can find information on 
performing the actions in the applicable propeller manufacturer's 
service documentation.
    (h) Perform the following actions:
    (1) Disassemble,
    (2) Clean,
    (3) Inspect for the following:
    (i) Cracks,
    (ii) Corrosion,
    (iii) Nicks,
    (iv) Scratches,
    (v) Blade minimum dimensions,
    (vi) Chemical conversion coat or paint or both applied over 
corrosion,
    (vii) Lack of chemical conversion coating,
    (viii) Lack of paint on internal surfaces,
    (ix) Bolts incorrectly torqued,
    (x) Incorrect parts,
    (xi) Incorrect installation of parts,
    (xii) Reinstallation of parts intended for one-time use, and
    (xiii) Lack of proper shot peening.
    (4) Repair and replace with serviceable parts, as necessary,
    (5) Reassemble and test.

Propellers With 10 Hours or More TIS Since Return to Service

    (i) Within 10 hours TIS after the effective date of this AD or 
one year after the effective date of this AD, whichever is earlier, 
perform the actions specified in paragraph (h) of this AD on 
propellers listed in Table 1 of this AD, that have 10 hours or more 
TIS since return to service by T and W Propellers, Inc. You can find 
information on performing the actions in the applicable propeller 
manufacturer's service documentation.

Required Actions Before Installation

    (j) After the effective date of this AD, do not install any 
propeller that has a SN listed in Table 1 of this AD returned to 
service by T and W Propellers, Inc. unless you have performed 
paragraph (h) of this AD on the propeller.

[[Page 39831]]

Alternative Methods of Compliance (AMOCs)

    (k) You must request AMOCs as specified in 14 CFR 39.19. All 
AMOCs must be approved by the Manager, Chicago Aircraft 
Certification Office, FAA.

Special Flight Permits

    (l) We will not issue special flight permits for propellers with 
fewer than 10 hours TIS since return to service by T and W 
Propellers, Inc.

Material Incorporated by Reference

    (m) None.

Related Information

    (n) The applicable propeller manufacturer's service documents 
contain instructions for performing the required overhaul actions.


    Issued in Burlington, Massachusetts, on June 26, 2003.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 03-16689 Filed 7-2-03; 8:45 am]
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