Airworthiness Directives; Continental Motors, Inc. Reciprocating Engines With Superior Air Parts, Inc. (SAP) Cylinder Assemblies Installed

[Federal Register Volume 79, Number 55 (Friday, March 21, 2014)]
[Rules and Regulations]
[Pages 15673-15675]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2014-06198]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-0051; Directorate Identifier 2007-NE-37-AD; 
Amendment 39-17801; AD 2014-05-29]
RIN 2120-AA64


Airworthiness Directives; Continental Motors, Inc. Reciprocating 
Engines With Superior Air Parts, Inc. (SAP) Cylinder Assemblies 
Installed

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are superseding airworthiness directive (AD) 2009-16-03 for 
certain Continental Motors, Inc. (CMI) IO-520, TSIO-520, and IO-550 
series reciprocating engines, with certain SAP replacement parts 
manufacturer approval (PMA) investment cast cylinder assemblies 
installed. AD 2009-16-03 required initial and repetitive inspections 
and compression tests to detect cracks in those cylinders. This new AD 
requires that additional engines be added to the applicability. This AD 
was prompted by the need to add to the applicability all other engine 
models approved for the use of CMI 520 and 550 cylinder assemblies, 
such as the CMI 470 series engines when modified by supplemental type 
certificate (STC), with affected SAP investment cast cylinder 
assemblies installed. We are issuing this AD to prevent the separation 
of the cylinder head, damage to the engine, and damage to the airplane.

DATES: This AD is effective April 25, 2014.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of April 25, 
2014.

ADDRESSES: For service information identified in this AD, contact 
Continental Motors, Inc., 2039 Broad St., Mobile, AL 36615; phone: 251-
438-3411; Web site: http://www.continentalmotors.aero/Support_Materials/Publications/Service_Bulletins/. You may view this service

[[Page 15674]]

information at the FAA, Engine & Propeller Directorate, 12 New England 
Executive Park, Burlington, MA. For information on the availability of 
this material at the FAA, call 781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2007-
0051; or in person at the Docket Management Facility between 9 a.m. and 
5 p.m., Monday through Friday, except Federal holidays. The AD docket 
contains this AD, the regulatory evaluation, any comments received, and 
other information. The address for the Docket Office (phone: 800-647-
5527) is Document Management Facility, U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE., Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Peter W. Hakala, Aerospace Engineer, 
Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76137; phone: 817-222-5145; fax: 817-222-5785; 
email: [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 to supersede AD 2009-16-03, Amendment 39-15986 (74 FR 38896, 
August 5, 2009), (``AD 2009-16-03''). AD 2009-16-03 applied to the 
specified products. The NPRM published in the Federal Register on 
September 13, 2013 (78 FR 56622). The NPRM proposed to continue to 
require initial and repetitive inspections and compression tests to 
detect cracks in certain replacement SAP PMA investment cast cylinder 
assemblies. The NPRM also proposed to require that additional engines 
be added to the applicability. We are issuing this AD to prevent the 
separation of the cylinder head, damage to the engine, and damage to 
the airplane.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the proposal 
and the FAA's response to each comment.

Request To Delete Requirement To Remove Cylinders After 12 Years

    SAP requested that we delete paragraph (i)(2), which requires the 
removal of cylinders after 12 years, stating that removal is not 
necessary if the required periodic 50-hour inspections show that the 
cylinders have no defects and are still airworthy.
    We disagree. The 12-year calendar requirement is due to the 
increased risk of environmental corrosion, a corresponding increase in 
potential for metal fatigue cracks, and the subsequent separation of 
the cylinder assemblies. The type certificate holder recommends removal 
and replacement of the cylinders no later than 12 years from date 
placed in service. We did not change this AD.

Request To Delete From Applicability the Additional Engines Identified 
by This Supersedure AD, and To Cancel This AD

    SAP requested that we delete from the applicability of this AD the 
Continental Motors, Inc. model CMI 470 series engines that are added to 
the applicability of this supersedure AD, and that we cancel this 
supersedure AD. SAP is not aware of any problems with the investment 
cast SAP cylinders installed on CMI model 470 series engines modified 
by STC to install SAP 520 cylinder assemblies.
    We disagree. We are not aware of data that would indicate that the 
failure mode of SAP 520 cylinder assemblies identified in this AD would 
not also exist in the comparatively small population of CMI model 470 
series engines modified by STC. We did not change this AD.

Request To Allow Reinstallation of Removed Cylinders

    SAP requested that we change paragraph (j) to allow reinstallation 
of cylinders that have been removed for maintenance because the removal 
and reinstallation of a cylinder does not impact cylinder head fatigue.
    We disagree. The purpose of this AD is to correct an unsafe 
condition by removing from service SAP investment cast cylinder 
assemblies. We did not change this AD.

Conclusion

    We reviewed the relevant data, considered the comments received, 
and determined that air safety and the public interest require adopting 
this AD as proposed.

Costs of Compliance

    We estimate that this AD affects 6,000 engines installed on 
airplanes of U.S. registry. We also estimate that it will take about 5 
hours to replace a cylinder, and 15 hours per engine to inspect the 
cylinders. The average labor rate is $85 per hour. Required parts will 
cost about $1,200 per cylinder. We anticipate that 4,000 cylinders will 
require replacement. Based on these figures, we estimate the total cost 
of this AD to U.S. operators to be $14,150,000.

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 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 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.

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:

[[Page 15675]]

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) 
2009-16-03, Amendment 39-15986 (74 FR 38896, August 5, 2009), and 
adding the following new AD:

2014-05-29 Continental Motors, Inc. (formerly Teledyne Continental 
Motors, Continental): Amendment 39-17801; Docket No. FAA-2007-0051; 
Directorate Identifier 2007-NE-37-AD.

(a) Effective Date

    This AD is effective April 25, 2014.

(b) Affected ADs

    This AD supersedes AD 2009-16-03, Amendment 39-15986 (74 FR 
38896, August 5, 2009).

(c) Applicability

    This AD applies to:
    (1) Continental Motors, Inc. (CMI) IO-520, TSIO-520, and IO-550 
series reciprocating engines with replacement Superior Air Parts, 
Inc. (SAP) parts manufacturer approval (PMA) investment cast 
cylinder assemblies, part numbers (P/Ns) SA52000-A1, SA52000-A20P, 
SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-
A20P, installed.
    (2) All other engine models approved for the use of CMI 520 and 
550 cylinder assemblies such as the CMI 470 series engines when 
modified by Supplemental Type Certificate (STC), with SAP investment 
cast cylinder assemblies, P/Ns SA52000-A1, SA52000-A20P, SA52000-
A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-A20P, 
installed.
    (3) This AD applies to all serial numbers for the P/Ns listed in 
paragraphs (c)(1) and (c)(2) of this AD.
    (4) If no SAP replacement cylinders were installed during engine 
maintenance since the CMI engines were new, then this AD does not 
apply.

(d) Unsafe Condition

    This AD was prompted by the need to add to the applicability all 
other engine models approved for the use of CMI 520 and 550 cylinder 
assemblies such as the CMI 470 series engines when modified by STC, 
with affected SAP investment cast cylinder assemblies installed. We 
are issuing this AD to prevent the separation of the cylinder head, 
damage to the engine, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(f) Identification of SAP Cylinder Assemblies

    Seeing the SAP cylinder assembly P/Ns referenced in paragraphs 
(c)(1) and (c)(2) of this AD may be difficult because the assembly 
P/Ns are stamped on the bottom cylinder flange. Therefore, you may 
review the engine maintenance records instead of the steps listed in 
paragraphs (f)(1) and (f)(2) of this AD, to see if the engine 
records identify the P/Ns of the cylinders installed. If the records 
do not identify the P/Ns of the cylinders installed, do the 
following:
    (1) Remove the valve cover from the cylinder assembly.
    (2) Look at the top of the cylinder head for the casting 
markings ``AMCAST'' or ``CP'' (note that the cylinder head casting 
part number, P/N SAC 52001 ``I'' or P/N SAC 55001 ``I'', will also 
be visible). If a cylinder head has these markings, do the steps 
required by paragraphs (g) through (j) of this AD.

(g) Initial Inspection of SAP Cylinder Assemblies

    For engines and cylinders listed in paragraphs (c)(1) and (c)(2) 
of this AD, with cylinders over 750 flight hours (FH) time-in-
service (TIS) on the effective date of this AD, do the following 
initial inspection within 25 FH TIS.
    (1) Inspect each cylinder head around the exhaust valve side for 
visual cracks or any signs of black combustion leakage.
    (2) Replace any cracked or leaking cylinders before further 
flight.
    (3) Perform a standard cylinder compression test. Guidance on 
standard cylinder compression tests can be found in Teledyne 
Continental Aircraft Engine Service Bulletin SB03-3, Differential 
Pressure Test and Borescope Inspection Procedures for Cylinders, 
dated March 28, 2003.
    (i) If the cylinder pressure gauge reads below 60 pounds per 
square inch, determine if the unacceptable pressure is due to a 
cracked cylinder.
    (ii) To check the cylinder, apply a 2-percent soapy water 
solution to the side of the leaking cylinder.
    (iii) If you see air bubbles, indicating air leakage, on the 
side of the cylinder head, or near the head-to-cylinder interface, 
replace the cylinder assembly before further flight.

(h) Repetitive Inspections of SAP Cylinder Assemblies

    Thereafter, repeat the cylinder visual inspections and 
compression tests specified in paragraphs (g)(1) through (g)(3)(iii) 
of this AD, within every 50 FH time-since-last inspection until the 
cylinder reaches the TIS as listed in paragraph (i) of this AD.

(i) Replacing SAP Cylinder Assemblies

    For installed cylinders, replace the affected SAP cylinders at 
the earliest of the following:
    (1) When the cylinder reaches the operating hours TIS between 
overhaul limits specified in Table 1, ``Engine Time Between 
Overhaul'', in Continental Motors Aircraft Engine Service 
Information Letter SIL98-9C, Revision C, dated July 17, 2013; or
    (2) When the cylinder reaches 12 calendar years-since-
installation.

(j) Prohibition Against Installing Certain P/Ns of SAP Cylinder 
Assemblies

    After the effective date of this AD, do not install or reinstall 
after any removal, any SAP investment cast cylinder assembly, P/Ns 
SA52000-A1, SA52000-A20P, SA52000-A21P, SA52000-A22P, SA52000-A23P, 
SA55000-A1, or SA55000-A20P, in any engine.

(k) Alternative Methods of Compliance (AMOCs)

    The Manager, Special Certification Office, may approve AMOCs to 
this AD. Use the procedures found in 14 CFR 39.19 to make your 
request.

(l) Special Flight Permits

    Under 14 CFR Part 39.23, we will not approve special flight 
permits for this AD for engines that have failed the visual 
inspection or the 50-hour periodic cylinder assembly compression 
test required by this AD.

(m) Related Information

    For more information about this AD, contact Peter W. Hakala, 
Aerospace Engineer, Special Certification Office, FAA, Rotorcraft 
Directorate, 2601 Meacham Blvd., Fort Worth, TX 76137; phone: 817-
222-5145; fax: 817-222-5785; email: [email protected].

(n) 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) Continental Motors Aircraft Engine Service Information 
Letter SIL98-9C, Revision C, dated July 17, 2013.
    (ii) Reserved.
    (3) For Continental Motors, Inc. service information identified 
in this AD, contact Continental Motors, Inc., 2039 Broad St., 
Mobile, AL 36615; phone: 251-438-3411; Web site: http://www.continentalmotors.aero/Support_Materials/Publications/Service_Bulletins.
    (4) You may view this service information at the FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, 
MA. For information on the availability of this material at the FAA, 
call 781-238-7125.
    (5) You may view this service information 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 March 4, 2014.
Colleen M. D'Alessandro,
Assistant Directorate Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2014-06198 Filed 3-20-14; 8:45 am]
BILLING CODE 4910-13-P

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