Airworthiness Directives; Sikorsky Aircraft Corporation-Manufactured (Sikorsky) Model Helicopters (Type Certificate Currently Held by Erickson Air-Crane Incorporated)

[Federal Register Volume 78, Number 211 (Thursday, October 31, 2013)]
[Rules and Regulations]
[Pages 65163-65166]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2013-24955]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2013-0454; Directorate Identifier 2009-SW-81-AD; 
Amendment 39-17621; AD 2013-20-15]
RIN 2120-AA64


Airworthiness Directives; Sikorsky Aircraft Corporation-
Manufactured (Sikorsky) Model Helicopters (Type Certificate Currently 
Held by Erickson Air-Crane Incorporated)

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are superseding Airworthiness Directive (AD) 97-19-10 for 
Sikorsky Aircraft Corporation-manufactured Model S-64E helicopters 
(type certificate currently held by Erickson Air-Crane Incorporated 
(Erickson)). AD 97-19-10 required inspecting and reworking the main 
gearbox (MGB) assembly second stage lower planetary plate (plate). This 
action establishes or reduces the life limits for certain flight-
critical components, removes from service various parts, requires 
repetitive inspections and other corrective actions, and requires 
replacing any cracked part discovered during an inspection. This AD is 
prompted by further analysis performed by the current type certificate 
holder and the service history of certain parts. The actions specified 
in this AD are intended to prevent a crack in a flight critical 
component, failure of a critical part, and subsequent loss of control 
of the helicopter.

DATES: This AD is effective December 5, 2013.
    The Director of the Federal Register approved the incorporation by 
reference of a certain document listed in this AD as of December 5, 
2013.

ADDRESSES: For service information identified in this AD, contact 
Erickson Air-Crane Incorporated, ATTN: Chris Erickson, Director of 
Regulatory Compliance, 3100 Willow Springs Rd, P.O. Box 3247, Central 
Point, OR 97502, telephone (541) 664-5544, fax (541) 664-2312, email 
address [email protected]. You may review a copy of the 
referenced service information at the FAA, Office of the Regional 
Counsel, Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth 
Texas 76137.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov or in person at the Docket Operations Office 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this AD, any incorporated-by-reference 
service information, the economic evaluation, any comments received, 
and other information. The street address for the Docket Operations 
Office (phone: 800-647-5527) is U.S. Department of Transportation, 
Docket Operations Office, M-30, West Building Ground Floor, Room W12-
140, 1200 New Jersey Avenue SE., Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Michael Kohner, Aerospace Engineer, 
Rotorcraft Certification Office, Rotorcraft Directorate, FAA, 2601 
Meacham Blvd., Fort Worth, TX 76137; telephone (817) 222-5170; email [email protected].

SUPPLEMENTARY INFORMATION:

Discussion

    On May 28, 2013, at 78 FR 31863, the Federal Register published our 
notice of proposed rulemaking (NPRM), which proposed to amend 14 CFR 
part 39 by adding an AD that would apply to Sikorsky Model CH-54A 
helicopters, now under the Erickson Air-Crane Incorporated (Erickson) 
Model S-64E type certificate. The NPRM proposed to supersede AD 97-19-
10 (62 FR 47933, September 12, 1997), which required inspecting and 
reworking the MGB assembly plate. Since AD 97-19-10 was issued, further 
analysis was performed by the current type certificate holder. As a 
result, the NPRM proposed to establish or revise the life limit for 
various parts, to remove various parts from service, to require various 
inspections and other maintenance actions, and to revise the component 
history card or equivalent record and the airworthiness limitations 
section of the maintenance manual accordingly. The proposed 
requirements were intended to prevent a crack in a flight critical 
component, failure of a critical part, and subsequent loss of control 
of the helicopter.

Comments

    We gave the public the opportunity to participate in developing 
this AD, but we did not receive any comments on the NPRM (78 FR 31863, 
May 28, 2013).

FAA's Determination

    We have reviewed the relevant information and determined that an 
unsafe condition exists and is likely to exist or develop on other 
products of these same type designs and that air safety and the public 
interest require

[[Page 65164]]

adopting the AD requirements as proposed.

Related Service Information

    Erickson Service Bulletin (SB) No. 64B General-1, Revision 19, 
dated September 15, 2010 (SB 64B General-1), specifies the retirement 
life for certain parts and assemblies as well as noting other 
maintenance actions. This and the previous revisions of SB 64B General-
1 contain reduced or new life limits for certain parts, parts which 
should be removed from service, other maintenance actions, and various 
other provisions for certain parts. We have also reviewed Erickson SB 
No. 64B10-3, Revision D, dated October 15, 2007, which provides 
ultrasonic inspection procedures for the Main Rotor (M/R) hub 
horizontal hinge pins.

Differences Between This AD and the Service Information

    This AD contains only those parts for the Model S-64E helicopters 
whose life limit has either been reduced or added for an existing P/N, 
whereas SB 64B General-1 also contains parts whose life limits have 
been extended. As a result, this proposed AD does not include all of 
the parts or P/Ns that are listed in SB 64B General-1.

Costs of Compliance

    We estimate that this AD will affect 13 helicopters of U.S. 
registry, and the proposed actions will take the following number of 
estimated work hours to accomplish:
    <bullet> 26 work hours (2 work hours per helicopter) for the fleet 
to review the helicopter records or to remove a part to determine if an 
affected part is installed;
    <bullet> 845 work hours (65 work hours per helicopter) for the 
fleet to replace the parts or assemblies on or before reaching the 
retirement lives stated in Table 1 of the AD, assuming an annual usage 
of 600 hours TIS;
    <bullet> 287 work hours per helicopter to replace all the parts or 
assemblies listed in Table 2 of the AD;
    <bullet> 130 work hours (10 work hours per helicopter) for the 
fleet to inspect the M/R servo housing assemblies for an oil leak, 
assuming each inspection would take approximately 0.25 work hour per 
helicopter and would be accomplished 40 times annually;
    <bullet> Approximately 293 work hours (22.5 work hours per 
helicopter) for the fleet to UT inspect each M/R hub horizontal hinge 
pin, assuming that each inspection would take 7.5 work hours per 
helicopter and would be accomplished 3 times annually;
    <bullet> 288 work hours (48 work hours per helicopter) to perform 
an MPI of each main gearbox second stage lower planetary plate and 
second stage planetary plate assembly assuming 6 helicopters would be 
inspected annually;
    <bullet> 192 work hours (32 work hours per helicopter) to perform 
an MPI of each M/R shaft and M/R shaft assembly, assuming 6 helicopters 
would be inspected annually, and
    <bullet> 96 work hours (32 work hours per helicopter) to perform an 
FPI of each M/R tandem servo housing assembly, assuming 3 helicopters 
would be inspected annually.
    Therefore, we estimate that it will take approximately 2,157 work 
hours to accomplish the proposed actions at a cost of $183,345, using 
an average labor rate $85 per work hour. Replacement parts will cost 
approximately:
    <bullet> $5,363,449 ($412,573 per helicopter) to replace the parts 
or assemblies on the entire fleet on or before reaching the proposed 
retirement lives, assuming parts for 13 helicopters would require 
replacement; and
    <bullet> $2,594,400 per helicopter to replace the parts or 
assemblies that are listed in Table 2 of the AD.
    Using these assumptions, the estimated total cost for the required 
parts will be approximately $7,957,849. Based on these estimated 
amounts using these assumptions, we estimate the total cost impact of 
the AD on the U.S. operators will be $8,141,194.

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

    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 this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866;
    (2) Is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979);
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction; and
    (4) 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 an economic evaluation of the estimated costs to comply 
with this AD and placed it in the AD docket.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 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 removing Airworthiness Directive (AD) 
97-19-10, Amendment 39-10130 (62 FR 47933, September 12, 1997), and 
adding the following new AD:

2013-20-15 SIKORSKY AIRCRAFT CORPORATION-MANUFACTURED (SIKORSKY) 
MODEL HELICOPTERS (TYPE CERTIFICATE CURRENTLY HELD BY ERICKSON AIR-
CRANE INCORPORATED): Amendment 39-17621; Docket No. FAA-2013-0454; 
Directorate Identifier 2009-SW-81-AD.

(a) Applicability

    This AD applies to Sikorsky Model CH-54A helicopters, now under 
the Erickson Air-Crane Incorporated (Erickson) Model S-64E type 
certificate, certificated in any category.

(b) Unsafe Condition

    This AD defines the unsafe condition as fatigue cracking in a 
flight critical component, failure of the component, and subsequent 
loss of control of the helicopter.

 (c) Affected ADs

    This AD supersedes AD 97-19-10, Amendment 39-10130 (62 FR 47933, 
September 12, 1997).

[[Page 65165]]

 (d) Effective Date

    This AD becomes effective December 5, 2013.

(e) Compliance

    You are responsible for performing each action required by this 
AD within the specified compliance time unless it has already been 
accomplished prior to that time.

(f) Required Actions

    (1) Before further flight, for each part listed in Table 1 to 
paragraph (f) of this AD:
    (i) Remove any part that has reached or exceeded its newly 
established or revised retirement life.
    (ii) Record the newly established or revised retirement life for 
each part on the component history card or equivalent record.
    (iii) Make pen and ink changes or insert a copy of this AD into 
the Airworthiness Limitations section of the maintenance manual to 
establish or revise the retirement life for each part that is listed 
in Table 1 to paragraph (f) of this AD.

   Table 1 to Paragraph (f) of This AD--Parts With New or Revised Life
                                 Limits
------------------------------------------------------------------------
          Part name              Part No. (P/N)        Retirement life
------------------------------------------------------------------------
Rod and bushing assembly,     6410-21090-012......  5,700 hours time-in-
 main rotor (M/R).                                   service (TIS) or 60
                                                     months since the
                                                     initial
                                                     installation on any
                                                     helicopter,
                                                     whichever occurs
                                                     first.
Rod and bushing assembly, M/  6410-21090-013 or -   5,700 hours TIS.
 R.                            014.
Lower plate, M/R hub........  6410-23009-102......  3,000 hours TIS.
Upper plate, M/R hub........  6410-23011-102......  3,000 hours TIS.
Swashplate, rotating, M/R...  6410-24002-101......  12,860 hours TIS.
Piston rod..................  6410-26005-104......  10,500 hours TIS.
Cylinder, damper assembly...  6410-26215-101......  7,300 hours TIS.
M/R blade...................  6415-20201-045 or -   3,300 hours TIS.
                               047.
M/R blade...................  6415-20201-048, -     20,000 hours TIS.
                               049, -050, or -051.
Truss assembly, stabilizer..  6420-66250-041......  4,720 hours TIS.
M/R shaft assembly (includes  6435-20078-014 or -   2,600 hours TIS.
 shaft, P/N 6435-20078-104).   015.
M/R shaft assembly (includes  6435-20078-016......  5,000 hours TIS.
 shaft, P/N 6435-20078-105).
Second stage planetary plate  6435-20231-012, -     1,300 hours TIS.
 assembly, main gearbox        014, or -015.
 assembly.
Second stage planetary plate  6435-20231-016......  2,600 hours TIS.
 assembly, main gearbox
 assembly.
Oil cooler and support        6435-60050-044......  9,885 hours TIS.
 assembly.
Tail rotor (T/R) blade......  65160-00001-042, -    23,300 hours TIS.
                               045, or -048.
T/R blade...................  65161-00001-042.....  23,300 hours TIS.
Hub, M/R....................  S1510-23001-005.....  3,000 hours TIS.
Spindle assembly, M/R.......  S1510-23027-5.......  5,675 hours TIS.
Horn assembly, M/R..........  S1510-23350-4, -6,    9,710 hours TIS.
                               or -8.
Sleeve, M/R.................  S1510-23351-2.......  12,930 hours TIS.
Sleeve lockwasher, M/R......  S1510-23458-0.......  2,700 hours TIS.
Cuff, M/R blade.............  S1515-20320-0.......  6,410 hours TIS.
Cuff, M/R blade.............  S1515-20320-001 or -  12,930 hours TIS.
                               002.
Piston assembly, M/R tandem   S1565-20443-0 or      8,100 hours TIS.
 servo.                        S1565-20443-301.
Fork assembly, M/R tandem     S1565-20449 or S1565- 8,100 hours TIS.
 servo.                        20449-301.
Bearing, T/R drive shaft....  SB1111-004 or -601..  1,000 hours TIS or
                                                     12 months while
                                                     installed on any
                                                     helicopter,
                                                     whichever occurs
                                                     first.
------------------------------------------------------------------------
Note to Table 1 to paragraph (f) of this AD: The list of parts in Table
  1 to paragraph (f) of this AD contains only a portion of the life-
  limited parts for this model helicopter and is not an all-inclusive
  list.

    (2) Before further flight, remove from service any part with a 
P/N listed in Table 2 to Paragraph (f) of this AD, regardless of the 
part's TIS. The part numbers listed in Table 2 to paragraph (f)(2) 
of this AD are not eligible for installation on any helicopter.

  Table 2 to Paragraph (f) of This AD--Parts To Be Removed From Service
------------------------------------------------------------------------
          Part name                               P/N
------------------------------------------------------------------------
Rod and bushing assembly, M/R  6410-21090-011.
M/R blade....................  6415-20001-013, -014, or -015.
Pylon stabilizer.............  6420-66201-010, -014, or -015.
M/R shaft assembly...........  6435-20078-013.
Oil cooler and support         6435-60050-043.
 assembly.
Pitch change link, rotary      65113-07100-046.
 rudder.
Spindle, M/R blade...........  S1510-23070-3.
------------------------------------------------------------------------

    (3) Within 20 hours TIS, and thereafter at intervals not to 
exceed 20 hours TIS, visually inspect each M/R servo and control arm 
assembly, P/N S1565-20421-10, -11, -041, or -043, and determine if 
there is any oil leaking from the M/R tandem servo housing assembly 
(servo housing), P/N S1565-20252-2. If there is any oil leaking from 
the servo housing, before further flight, replace the M/R servo and 
control arm assembly.
    (4) Within 20 hours TIS or before reaching 1,120 hours TIS, 
whichever occurs later, and thereafter at intervals not to exceed 
200 hours TIS or 12 months, whichever occurs first, ultrasonic (UT) 
inspect each M/R hub horizontal hinge pin (hinge pin), P/N S1510-
23099-1 or P/N S1510-23099-001, for a crack in accordance with the

[[Page 65166]]

Accomplishment Instructions, paragraphs 2.A through 2.C, of Erickson 
Service Bulletin No. 64B10-3, Revision D, dated October 15, 2007, 
except you are not required to contact Erickson nor send hinge pins 
to them. A non-destructive testing (NDT) UT Level I Special, Level 
II, or Level III inspector who is qualified under the guidelines 
established by ASNT SNT-TC-1A, ISO 9712, or an FAA-accepted 
equivalent qualification standard for NDT inspection and evaluation, 
must perform the UT inspection.
    (5) Within 150 hours TIS or before reaching 1,450 hours TIS, 
whichever occurs later, perform a fluorescent-magnetic particle 
inspection (MPI) of each second stage planetary plate assembly, P/N 
6435-20231-016, for a crack.
    (6) Within 150 hours TIS or before reaching 1,450 hours TIS, 
whichever occurs later, and thereafter at intervals not to exceed 
650 hours TIS, perform an MPI of each M/R shaft, P/N 6435-20078-104, 
for a crack, paying particular attention to the lower spline area.
    (7) Within 150 hours TIS or before reaching 1,450 hours TIS, 
whichever occurs later, and thereafter at intervals not to exceed 
1,450 hours TIS, perform an MPI of each M/R shaft, P/N 6435-20078-
105, for a crack, paying particular attention to the lower spline 
area.
    (8) Within 150 hours TIS or before reaching 3,375 hours TIS, 
whichever occurs later, and thereafter at intervals not to exceed 
3,375 hours TIS, perform a fluorescent penetrant inspection of each 
housing lug on each servo housing, P/N S1565-20252-2, for a crack.
    (9) At each overhaul of the main gearbox assembly, P/N 6435-
20400-053, -054, -058, -060, -062, -063, -064, -065, or -066, 
perform an MPI of the entire shaft of each M/R shaft assembly, P/N 
6435-20078-014, -015, or -016, for a crack, paying particular 
attention to the rotating swashplate spherical bearing ball travel 
area, which is located approximately ten inches above the upper 
roller bearing journal shoulder.
    (10) If there is a crack in any part, before further flight, 
replace the cracked part.
    (11) At each overhaul of the damper assembly, P/N 6410-26200-
042, replace the following parts with airworthy parts that have zero 
(0) hours TIS:
    (i) All Air Force-Navy Aeronautical Standard (AN), Aerospace 
Standard (AS), Military Standard (MS), and National Aerospace 
Standard (NAS) nuts, bolts, washers, and packings, except packing, 
P/N MS28775-011, installed on stud, P/N SHF111-11SN-12A;
    (ii) Lock washer, P/N SS5073-2;
    (iii) Nut, P/N SS5081-05;
    (iv) Felt seal, P/N S1510-26017;
    (v) Retaining ring, P/N UR106L; and
    (vi) Nut, P/N 6410-26214-101.

(g) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Rotorcraft Certification Office, FAA, may 
approve AMOCs for this AD. Send your proposal to: Michael Kohner, 
Aerospace Engineer, Rotorcraft Certification Office, Rotorcraft 
Directorate, FAA, 2601 Meacham Blvd., Fort Worth, TX 76137; 
telephone (817) 222-5170; email [email protected].
    (2) For operations conducted under a 14 CFR part 119 operating 
certificate or under 14 CFR part 91, subpart K, we suggest that you 
notify your principal inspector, or lacking a principal inspector, 
the manager of the local flight standards district office or 
certificate holding district office before operating any aircraft 
complying with this AD through an AMOC.

(h) Additional Information

    Erickson Service Bulletin No. 64B General-1, Revision 19, dated 
September 15, 2010, which is not incorporated by reference, contains 
additional information about the subject of this AD. For service 
information identified in this AD, contact Erickson Air-Crane 
Incorporated, ATTN: Chris Erickson, Director of Regulatory 
Compliance, 3100 Willow Springs Rd., P.O. Box 3247, Central Point, 
OR 97502, telephone (541) 664-5544, fax (541) 664-2312, email 
address [email protected]. You may review a copy of 
this information at the FAA, Office of the Regional Counsel, 
Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas 
76137.

(i) Subject

    Joint Aircraft Service Component (JASC) Code: 6200: Main Rotor 
System; 6300: Main Rotor Drive System; 6410: Tail Rotor Blades; 
6500: Tail Rotor Drive System.

(j) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Erickson Service Bulletin No. 64B10-3, Revision D, dated 
October 15, 2007.
    (ii) Reserved.
    (3) For Erickson service information identified in this AD, 
contact Erickson Air-Crane Incorporated, ATTN: Chris Erickson, 
Director of Regulatory Compliance, 3100 Willow Springs Rd, P.O. Box 
3247, Central Point, OR 97502, telephone (541) 664-5544, fax (541) 
664-2312, email address [email protected].
    (4) You may view this service information that is incorporated 
by reference at FAA, Office of the Regional Counsel, Southwest 
Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas 76137.
    (5) You may also view this service information that is 
incorporated by reference 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 Fort Worth, Texas, on September 25, 2013.
Lance T. Gant,
Acting Directorate Manager, Rotorcraft Directorate, Aircraft 
Certification Service.
[FR Doc. 2013-24955 Filed 10-30-13; 8:45 am]
BILLING CODE 4910-13-P

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