Airworthiness Directives; Robinson Helicopter Company Model R22-Series Helicopters

[Federal Register Volume 69, Number 183 (Wednesday, September 22, 2004)]
[Rules and Regulations]
[Pages 56688-56690]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-21269]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2004-SW-15-AD; Amendment 39-13803; AD 2004-19-09]
RIN 2120-AA64


Airworthiness Directives; Robinson Helicopter Company Model R22-
Series Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment supersedes an existing emergency airworthiness 
directive (AD) for the Robinson Helicopter Company (Robinson) Model 
R22, R22 Alpha, R22 Beta, and R22 Mariner helicopters, that currently 
requires track-and-balancing certain main rotor blades (blades), 
replacing blades, and determining the age of each blade and revising 
the component history card or equivalent maintenance record. This 
amendment requires the same actions, but changes the applicability and 
adds clarifying language. It also prohibits the issuance of special 
flight permits, which the existing AD allows. This amendment is 
prompted by the need to clarify the existing AD language. The actions 
specified by this AD are intended to prevent a fatigue crack, blade 
failure, and subsequent loss of control of the helicopter.

DATES: Effective October 7, 2004.
    Comments for inclusion in the Rules Docket must be received on or 
before November 22, 2004.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Office of the Regional Counsel, Southwest Region, 
Attention: Rules Docket No. 2004-SW-15-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].

[[Page 56689]]


FOR FURTHER INFORMATION CONTACT: Fred Guerin, Aviation Safety Engineer, 
FAA, Los Angeles Aircraft Certification Office, Airframe Branch, 3960 
Paramount Blvd., Lakewood, California 90712, telephone (562) 627-5232, 
fax (562) 627-5210.

SUPPLEMENTARY INFORMATION: On March 18, 2004, the FAA issued emergency 
AD 2004-06-52, Docket 2004-SW-01-AD, to require:
    <bullet> Within 10 hours time-in-service (TIS) or 30 days, 
whichever occurs first, track-and-balancing blades that are 5 years old 
or have 1,000 hours TIS;
    <bullet> Replacing the blades with airworthy blades before further 
flight if an abnormal increase in vibration occurs within 5 hours TIS 
after the last track-and-balance;
    <bullet> Within 10 hours TIS or 30 days, whichever occurs first, 
for helicopters with blades, part number (P/N) A016-1, replacing the 
blades with airworthy blades other than blades, P/N A016-1, on or 
before reaching 2,000 hours TIS;
    <bullet> Within 10 hours TIS or 30 days, whichever occurs first, 
for helicopters with blades, P/N A016-2, replacing the blades with 
airworthy blades other than blades, P/N A016-1, on or before reaching 
2,200 hours TIS or 10 years, whichever occurs first; and
    <bullet> Within 10 hours TIS or 30 days, whichever occurs first, 
determining the age of each blade and revising the component history 
card or equivalent maintenance record for blades, P/N A016-2, by adding 
a 10-year retirement life to the current 2,200 hours TIS retirement 
life.
    That action was prompted by two accidents that occurred in 
Australia and Israel that were attributed to failure of a blade. 
Investigation revealed that corrosion from water penetration initiated 
a fatigue crack in a blade. Information from the accident 
investigations revealed that the cracked blades manifested an increase 
in helicopter vibration. Following a track-and-balance of the blades, 
the vibrations would go back to normal for a short time and then slowly 
increase again until blade failure occurred. That condition, if not 
corrected, could result in a fatigue crack, blade failure, and 
subsequent loss of control of the helicopter.
    Since issuing that AD, several commenters have called regarding the 
following issues:
    <bullet> The AD does not include the start date for determining the 
age of the blades on Model R22 helicopters that have been overhauled by 
the manufacturer since these helicopters are returned to the owner with 
new blades, but only have a ``return-to-service tag''. The FAA agrees, 
and has included specific instructions for overhauled helicopters in 
this AD.
    <bullet> Paragraph (d) of the emergency AD is unclear and has been 
interpreted by some to mean that all Model R22 helicopters with blades, 
P/N A016-2, installed, are grounded within 10 hours TIS or 30 days. 
While the FAA does not understand this interpretation, we have reworded 
the paragraph in this AD in an attempt to make it clearer. These blades 
must be replaced with airworthy blades on or before reaching their 
retirement life.
    <bullet> Are the R22 Model Beta II and HP helicopters affected by 
the AD since they are not specifically listed in the Applicability 
section of the AD? The R22 Model Beta II and HP helicopters are 
commercial names for the R22 Beta and R22 and are not shown on the 
helicopter's type certificate. The required identification plate for 
each helicopter must contain the Model designation. These data plate 
model numbers are the ones listed in the type certificate and, as 
appropriate, in our ADs. However, the applicability statement has been 
restated in terms of the Model R22-series helicopters with blades, P/N 
A0126-1 or A016-2, installed. Our intent was and is to include in the 
applicability ALL Model R-22 helicopters with the affected blades 
installed, regardless of their commercial designation.
    <bullet> ``Yellow tags'' are issued for any return to service of a 
part, whether new or not; does any ``yellow tag'' constitute the start 
of the calendar life of the blade? The AD has been reworded to clarify 
that only ``yellow tags'' delivered with the blade when new may be used 
to start the calendar life of the blade.
    These changes justify issuing this superseding AD instead of 
publishing Emergency AD 2004-06-52 as a Final Rule in the Federal 
Register.
    Since an unsafe condition has been identified that is likely to 
exist or develop on other Robinson Model R22 helicopters of the same 
type design, this AD supersedes AD 2004-06-52 to require:
    <bullet> Within 10 hours TIS or 30 days, whichever occurs first, 
tracking-and-balancing blades, P/N A016-2, that are 5 or more years 
old, or have 1,000 or more hours TIS;
    <bullet> Replacing the blades with airworthy blades, P/N A016-2, 
before further flight if an abnormal increase in vibration occurs 
within 5 hours TIS after the last track-and-balance;
    <bullet> Within 10 hours TIS or 30 days, whichever occurs first, 
for helicopters with blades, P/N A016-1, replacing the blades with 
airworthy blades, P/N A016-2 or A016-4;
    <bullet> Within 10 hours TIS or 30 days, whichever occurs first, 
for helicopters with blades, P/N A016-2, replacing the blades with 
airworthy blades on or before reaching 2,200 hours TIS or 10 years, 
whichever occurs first; and
    <bullet> Within 10 hours TIS or 30 days, whichever occurs first, 
determining the age of each blade and revising the component history 
card or equivalent maintenance record for blades, P/N A016-2, by adding 
a 10-year retirement life to the current 2,200 hours TIS retirement 
life.
    The short compliance time involved is required because the 
previously described critical unsafe condition can adversely affect the 
controllability and structural integrity of the helicopter. Therefore, 
the previously stated actions are required within a short timeframe and 
this AD must be issued immediately.
    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.
    The FAA estimates that this AD will affect 923 helicopters of U.S. 
registry. Track-and-balancing the blades, revising the component 
history card and maintenance manual, determining the age of each blade, 
and replacing blades, if necessary, will take approximately 11 work 
hours per helicopter to accomplish at an average labor rate of $65 per 
work hour. Required parts will cost approximately $25,000 (for 2 
blades) per helicopter. Based on these figures, we estimate the total 
cost impact of the AD on U.S. operators to be $7,584,945, assuming that 
most blades currently in service reach the TIS retirement life before 
reaching the calendar retirement life, and that at most, 277 
helicopters will need their blades replaced.

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

[[Page 56690]]

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 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 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. 2004-SW-15-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

0
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

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. Section 39.13 is amended by adding a new airworthiness directive 
(AD), Amendment 39-13803, to read as follows:

2004-19-09 Robinson Helicopter Company: Amendment 39-13803. Docket 
No. 2004-SW-15-AD. Supersedes Emergency AD 2004-06-52, Docket No. 
2004-SW-01-AD.

    Applicability: Model R22-series helicopters, with a main rotor 
blade (blade), part number (P/N) A016-1 or A016-2, installed, 
certificated in any category.
    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent a fatigue crack, blade failure, and subsequent loss 
of control of the helicopter, accomplish the following:
    (a) Within 10 hours time-in-service (TIS) or 30 days, whichever 
occurs first, for helicopters with blades, P/N A016-2, that are 5 or 
more years old, or have 1,000 or more hours TIS, track-and-balance 
the blades. If an abnormal increase in vibration occurs within 5 
hours TIS after the last track and balance, before further flight, 
replace the blades with airworthy blades, P/N A016-2, that are less 
than 10 years old and have less than 2,200 hours TIS, or airworthy 
blades, P/N A016-4, that are less than 12 years old and have less 
than 2,200 hours TIS.
    (b) Within 10 hours TIS or 30 days, whichever occurs first, for 
helicopters with blades, P/N A016-1, replace the blades with 
airworthy blades, P/N A016-2 or A016-4.
    (c) Within 10 hours TIS or 30 days, whichever occurs first, 
determine the age of each blade:
    (1) For a zero-hour TIS (new) blade delivered with an 
Airworthiness Approval tag, the time begins on the date stated on 
that tag. For a blade older than 9 years that pre-dates the use of 
the Airworthiness Approval tag and was delivered as a new blade with 
a ``yellow tag,'' the time begins on the date stated on that tag. 
Any subsequent yellow tag issued for a blade after the blade was 
placed into service is not valid for determining the original 
manufacture date.
    (2) For a new blade that has neither an Airworthiness Approval 
tag nor a yellow tag because it was delivered on a factory-new 
helicopter, the time begins on the date stated on the original 
Airworthiness Certificate as documented in the aircraft maintenance 
records.
    (3) For a new blade installed on an overhauled helicopter, the 
time begins on the date the helicopter was returned to service after 
overhaul as documented in the aircraft logbook or work report.
    (4) For all other blades, the time begins on the date of 
manufacture. This date can be obtained from the manufacturer by 
providing them the serial number and part number.
    (d) Within 10 hours TIS or 30 days, whichever occurs first, for 
helicopters with blades, P/N A016-2, replace the blades with 
airworthy blades on or before reaching 2,200 hours TIS or 10 years, 
whichever occurs first.
    (e) Within 10 hours TIS or 30 days, whichever occurs first, 
revise the component history card or equivalent maintenance record 
for blades, P/N A016-2, by adding a 10-year retirement life to the 
current 2,200 hours TIS retirement life.
    (f) Revise the Airworthiness Limitations section of the 
applicable maintenance manual by adding a new retirement life of 10 
years to the current 2,200 hours TIS retirement life for blades, P/N 
A016-2.

    Note: Robinson Model R22 Maintenance Manual, dated January 16, 
2004, contains the revised Airworthiness Limitations section.

    (g) 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 Los Angeles Aircraft Certification Office, Transport 
Airplane Directorate, FAA, for information about previously approved 
alternative methods of compliance.
    (h) Special flight permits will not be issued.
    (i) This amendment becomes effective on October 7, 2004.

    Issued in Fort Worth, Texas, on September 16, 2004.
David A. Downey,
Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 04-21269 Filed 9-21-04; 8:45 am]
BILLING CODE 4910-13-P

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