Airworthiness Directives; McCauley Propeller Systems Five-Blade Propeller Assemblies

[Federal Register Volume 70, Number 229 (Wednesday, November 30, 2005)]
[Rules and Regulations]
[Pages 71756-71758]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-23431]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-22690; Directorate Identifier 2005-NE-35-AD; 
Amendment 39-14388; AD 2005-24-08]
RIN 2120-AA64


Airworthiness Directives; McCauley Propeller Systems Five-Blade 
Propeller Assemblies

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain McCauley Propeller Systems propeller assemblies installed on 
BAE Systems (Operations) Limited Jetstream model 4100 series airplanes. 
This AD requires removing certain propeller hubs from service at new 
reduced life limits and eddy current inspections (ECIs) of the 
propeller hub. This AD results from three reports of cracked propeller 
hubs. We are issuing this AD to prevent cracked propeller hubs, which 
could cause failure of the propeller hub, blade separation, and loss of 
control of the airplane.

DATES: This AD becomes effective December 15, 2005. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of December 15, 2005.
    We must receive any comments on this AD by January 30, 2006.

ADDRESSES: Use one of the following addresses to comment on this AD:
    <bullet> DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
    <bullet> Government-wide rulemaking Web site: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
    <bullet> Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street, SW., Nassif Building, Room PL-401, 
Washington, DC 20590-0001.
    <bullet> Fax: (202) 493-2251.
    <bullet> Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street, SW., Washington, DC, between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    Contact McCauley Propeller Systems, P.O. Box 7704, Wichita, KS 
97277-7704, for the service information referenced in this AD.

FOR FURTHER INFORMATION CONTACT: Jeff Janusz, Aerospace Engineer, 
Wichita Aircraft Certification Office, FAA, Small Airplane Directorate, 
1801 Airport Road, Wichita, KS 67209, telephone: (316) 946-4148; fax: 
(316) 946-4107.

SUPPLEMENTARY INFORMATION: In August 2003, we issued AD 2003-17-10 
which requires initial and repetitive fluorescent penetrant inspection 
or ultrasonic inspection of propeller blade retention areas for cracks, 
replacement of high time propeller blades, and a onetime inspection of 
propeller hubs. That AD resulted from four earlier reports of cracks in 
propeller blade shanks. Since we issued AD 2003-17-10, we received 
three more reports of cracked hubs. In November 2004, we issued AD 
2004-23-16 which requires a onetime ECI of the propeller hub for 
cracks, and if necessary, replacing the propeller assembly. That AD 
also captured inspection results for the propeller hubs installed on 
the Jetstream model 4100 fleet.
    We received field reports that during taxi and ground maneuvering, 
certain airplane operators might be violating the published and 
placarded propeller ground revolutions-per-minute (rpm) restrictions. 
Operating in the restricted rpm range during ground operation can 
excite a natural propeller blade frequency that creates damaging stress 
loadings on the propeller blades and hub. The stress loadings can cause 
cracks, leading to propeller structural failure.
    Additionally, some operators use a water-methanol assist system to 
provide more engine power during certain operating conditions. The 
operating procedures for the water-methanol assist system define an 
airplane brakes-locked condition. Testing has shown that using the 
water-methanol assist system with airplane brakes locked creates 
propeller loadings exceeding structural fatigue limits of the propeller 
hub. This condition, if not corrected, could result in cracked hubs, 
which could cause failure of the propeller hub, blade separation, and 
loss of control of the airplane.

Relevant Service Information

    We reviewed and approved the technical contents of McCauley Alert 
Service Bulletin (ASB) No. ASB250, dated September 12, 2005. This ASB 
introduces new lower life limits for the propeller hubs identified in 
this AD, and describes ECI procedures for them.

FAA's Determination and Requirements of This AD

    The unsafe condition described previously is likely to exist or 
develop on other McCauley propeller assemblies, P/Ns B5JFR36C1101/
114GCA-0, C5JFR36C1102/L114GCA-0, B5JFR36C1103/114HCA-0, and 
C5JFR36C1104/L114HCA-0, installed on BAE Systems (Operations) Limited 
Jetstream model 4100 series airplanes. We are issuing this AD to 
prevent cracked hubs, which could cause failure of the propeller hub, 
blade separation, and loss of control of the airplane. This AD 
requires:
    <bullet> Removing any propeller hub from service that is currently, 
or ever was, operated on an engine with a water-methanol assist system, 
not later than 6,000 hours time-in-service (TIS).
    <bullet> Removing any other propeller hub from service not later 
than 18,000 hours TIS.
    <bullet> Removing any propeller hub from service that exceeds its 
life limit on the effective date of this AD, within 50 hours TIS after 
the effective date of this AD.
    <bullet> That any propeller hub removed from service after 
exceeding its life limit must not be returned to service on any 
installation.
    <bullet> For all installed propeller hubs, performing an ECI within 
200 hours TIS or 60 days after the effective date of this AD, whichever 
occurs first.
    <bullet> Thereafter, for all installed propeller hubs with 12,000 
or more hours TIS, performing repetitive ECIs within 1,800 hours TIS or 
12 months, whichever occurs first.
    You must use the service information described previously to 
perform the actions required by this AD. This AD does not require 
repetitive inspections for propeller hubs that ever operated on, or are 
currently operating on, engines with a water-methanol assist system,

[[Page 71757]]

due to the 6,000 hours TIS hub reduced life limit.

FAA's Determination of the Effective Date

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

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 send us any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. FAA-2005-22690; 
Directorate Identifier 2005-NE-35-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify it.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this AD. Using the search function of the DMS Web 
site, anyone can find and read the comments in any of our dockets. This 
includes the name of the individual who sent the comment (or signed the 
comment on behalf of an association, business, labor union, etc.). You 
may review the DOT's complete Privacy Act Statement in the Federal 
Register published on April 11, 2000 (65 FR 19477-78) or you may visit 
http://dms.dot.gov.

Examining the AD Docket

    You may examine the docket that contains the AD, any comments 
received, and any final disposition in person at the Docket Management 
Facility Docket Offices between 9 a.m. and 5 p.m., Monday through 
Friday, except Federal holidays. The Docket Office (telephone (800) 
647-5227) is located on the plaza level of the Department of 
Transportation Nassif Building at the street address stated in 
ADDRESSES. Comments will be available in the AD docket shortly after 
the DMS receives them.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, 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.

Regulatory Findings

    We 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 at the 
address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
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:

2005-24-08 McCauley Propeller Systems: Amendment 39-14388. Docket 
No. FAA-2005-22690; Directorate Identifier 2005-NE-35-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective December 
15, 2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to McCauley Propeller Systems propeller 
assemblies, part numbers (P/Ns) B5JFR36C1101/114GCA-0, C5JFR36C1102/
L114GCA-0, B5JFR36C1103/114HCA-0, and C5JFR36C1104/L114HCA-0. These 
propeller assemblies are installed on BAE Systems (Operations) 
Limited Jetstream Model 4100 series airplanes.

Unsafe Condition

    (d) This AD results from three reports of cracked propeller 
hubs. We are issuing this AD to prevent cracked propeller hubs, 
which could cause failure of the propeller hub, blade separation, 
and loss of control of the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

Propeller Hub Reduced Life Limits

    (f) Remove any propeller hub from service that is currently, or 
ever was, operated on an engine with a water-methanol assist system, 
not later than 6,000 hours time-in-service (TIS).
    (g) Remove any other propeller hub from service not later than 
18,000 hours TIS.
    (h) Remove any propeller hub from service that exceeds its life 
limit on the effective date of this AD, within 50 hours TIS after 
the effective date of this AD.

Prohibition of Hubs Exceeding Life Limit

    (i) Any propeller hub removed from service after exceeding its 
life limit must not be returned to service on any installation.

Propeller Hub Initial Inspection

    (j) For all installed propeller hubs, perform an eddy current 
inspection (ECI) within 200 hours TIS or 60 days after the effective 
date of this AD, whichever occurs first. Use the Accomplishment 
Instructions of McCauley Alert Service Bulletin (ASB) No. ASB250, 
dated September 12, 2005, to do the inspection.

Propeller Hub Repetitive Inspections

    (k) Thereafter, for all installed propeller hubs with 12,000 or 
more hours TIS:
    (1) Perform repetitive ECIs within 1,800 hours TIS or 12 months, 
whichever occurs first.
    (2) Use the Accomplishment Instructions of McCauley ASB No. 
ASB250, dated September 12, 2005, to do the inspections.

[[Page 71758]]

    (l) This AD does not require repetitive inspections for 
propeller hubs that ever operated on, or are currently operating on, 
engines with a water-methanol assist system, due to the 6,000 hours 
TIS hub reduced life limit.

Reporting Requirements

    (m) Report within 10 calendar days of the inspection, the 
results that equal or exceed the reject criteria to:
    (1) The FAA, Wichita Aircraft Certification Office, 1801 Airport 
Road, Room 100, Wichita, KS 67209, Attention: Jeff Janusz, telephone 
(316) 946-4148; e-mail: [email protected]; and
    (2) McCauley Propeller Systems, P.O. Box 7704, Wichita, KS 
97277-7704.
    (3) Reporting requirements have been approved by the Office of 
Management and Budget (OMB) and assigned OMB control number 2120-
0056.

Alternative Methods of Compliance

    (n) The Manager, Wichita Aircraft Certification Office, has the 
authority to approve alternative methods of compliance for this AD 
if requested using the procedures found in 14 CFR 39.19.

Related Information

    (o) None.

Material Incorporated by Reference

    (p) You must use McCauley Alert Service Bulletin No. ASB250, 
dated September 12, 2005, to perform the inspections required by 
this AD. The Director of the Federal Register approved the 
incorporation by reference of this service bulletin in accordance 
with 5 U.S.C. 552(a) and 1 CFR part 51. Contact McCauley Propeller 
Systems, P.O. Box 7704, Wichita, KS 97277-7704, for a copy of this 
service information. You may review copies at the Docket Management 
Facility; U.S. Department of Transportation, 400 Seventh Street, 
SW., Nassif Building, Room PL-401, Washington, DC 20590-0001, on the 
Internet at http://dms.dot.gov, or at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued in Burlington, Massachusetts, on November 21, 2005.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-23431 Filed 11-29-05; 8:45 am]
BILLING CODE 4910-13-P

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