Airworthiness Directives; Bell Helicopter Textron, Inc. Model 204B, 205A, and 205A-1 Helicopters

[Federal Register Volume 64, Number 155 (Thursday, August 12, 1999)]
[Rules and Regulations]
[Pages 43905-43907]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 99-20754]



[[Page 43905]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 98-SW-73-AD; Amendment 39-11252; AD 99-17-03]
RIN 2120-AA64


Airworthiness Directives; Bell Helicopter Textron, Inc. Model 
204B, 205A, and 205A-1 Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), applicable to Bell Helicopter Textron, Inc. (BHTI) Model 204B, 
205A, and 205A-1 helicopters, that currently requires modifying and 
inspecting the vertical fin spar (fin spar) for cracks. This amendment 
requires modification and visual and dye-penetrant inspections of the 
fin spar for cracks, and if a crack is discovered, replacing the fin 
spar. A tapping test for disbonding and replacing certain fin spars 
within 12 calendar months is also required. This amendment is prompted 
by an accident involving a Model 205A-1 helicopter and four other 
accidents involving helicopters of similar type design. The actions 
specified by this AD are intended to prevent failure of the fin spar, 
loss of the tail rotor, and subsequent loss of control of the 
helicopter.

DATES: Effective September 16, 1999.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of September 16, 1999.

ADDRESSES: The service information referenced in this AD may be 
obtained from Bell Helicopter Textron, Inc., P.O. Box 482, Fort Worth, 
Texas 76101, telephone (817) 280-3391, fax (817) 280-6466. This 
information may be examined at the FAA, Office of the Regional Counsel, 
Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas; or 
at the Office of the Federal Register, 800 North Capitol Street, NW., 
suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Harry Edmiston, Aerospace Engineer, 
Rotorcraft Certification Office, Rotorcraft Directorate, FAA, 2601 
Meacham Blvd., Fort Worth, Texas 76137, telephone (817) 222-5158, fax 
(817) 222-5783.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 97-18-11, 
Amendment 39-10520 (63 FR 26429), applicable to BHTI Model 204B, 205A, 
and 205A-1 helicopters, was published in the Federal Register on May 
26, 1999 (64 FR 28420). That action proposed to require initial and 
repetitive inspections of the fin spar for cracks. Also proposed was a 
requirement to replace the fin spar within 12 calendar months. 
Replacing the fin spar with a FAA-approved fin spar configuration that 
satisfies the structural fatigue requirement of repeated high torque 
events would constitute a terminating action for the requirements of 
the AD. That action was prompted by an accident involving a Model 205A-
1 helicopter and four other accidents involving helicopters of similar 
type design.
    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. No comments were received on the 
proposal or the FAA's determination of the cost to the public. The FAA 
has determined that air safety and the public interest require the 
adoption of the rule as proposed.
    The FAA estimates that 150 helicopters of U.S. registry will be 
affected by this AD, that it will take approximately 8 work hours per 
helicopter to accomplish the initial inspection and 0.5 work hour to 
accomplish each repetitive inspection. Replacing the fin spar will take 
approximately 150 work hours. The average labor rate is $60 per work 
hour. The manufacturer has stated that parts will be provided at no 
cost. Based on these figures, the total cost impact of the proposed AD 
on U.S. operators is estimated to be $76,500 for the initial inspection 
and one repetitive inspection, and $1,350,000 to replace the fin spars 
on the entire fleet.
    The regulations adopted herein will not have substantial direct 
effects 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, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    For the reasons discussed above, I certify that this action (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); 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. A final evaluation has been prepared for this action 
and it is contained in the Rules Docket. A copy of it 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, Incorporation by 
reference, Safety.

Adoption of the Amendment

    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

    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]

    2. Section 39.13 is amended by removing Amendment 39-10520 (63 FR 
26429, May 13, 1998), and by adding a new airworthiness directive (AD), 
Amendment 39-11252, to read as follows:

AD 99-17-03  Bell Helicopter Textron, Inc.: Amendment 39-11252. 
Docket No. 98-SW-73-AD. Supersedes AD 97-18-11, Amendment 39-10520, 
Docket No. 97-SW-32-AD.

    Applicability: Model 204B helicopters with vertical fin spar 
(fin spar), part number (P/N) 205-030-899-001, -089, P/N 205-030-
846-001, -003, -047, -049, or P/N 204-030-825-063, -065, installed, 
and Model 205A and 205A-1 helicopters, with fin spar, P/N 205-030-
899-101, P/N 205-030-846-087, -089, or P/N 205-032-851-003, -007, -
009, installed, certificated in any category.

    Note 1: This AD applies to each helicopter identified in the 
preceding applicability provision, regardless of whether it has been 
otherwise modified, altered, or repaired in the area subject to the 
requirements of this AD. For helicopters that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (c) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent failure of the fin spar, loss of the tail rotor, and 
subsequent loss of control of the helicopter, accomplish the 
following:

[[Page 43906]]

    (a) For Model 204B helicopters:
    (1) Within 8 hours time-in-service (TIS), modify the vertical 
fin and visually inspect the fin spar for cracks in accordance with 
Part I (A1), paragraphs 1 through 5 of Bell Helicopter Textron 
(BHTI) Alert Service Bulletin (ASB) 204B-98-50, dated October 22, 
1998.
    (i) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (ii) After inspection, apply MIL-PRF-81352 TYI clear lacquer or 
equivalent to the inside of the two lower rivet holes and on the 
surface where paint and primer were removed. Spray, brush, or wipe 
on a protective coat of MIL-C-16173, Grade 2, or equivalent, over 
the clear lacquer. To facilitate subsequent inspections, do not 
replace the two lower rivets. See Figure 2 of BHTI ASB 204B-98-50, 
dated October 22, 1998.

    Note 2: BHTI-MED-SRM-1, pages 3-36 through 3-38, pertain to the 
installation of Hi-Loks.

    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. An existing 
edge distance less than 1.5 times the diameter of the drill or 
reamed hole must have FAA approval of the reworked area before 
proceeding.
    (iv) Fasten the forward left-hand fin skin to the spar assembly 
using Hi-Loks and blind rivets as specified in Figure 2 of BHTI ASB 
204B-98-50, dated October 22, 1998.
    (v) Refinish the reworked area.
    (2) After initial modification and inspection of the fin, 
thereafter inspect the fin spar for cracks at intervals not to 
exceed 8 hours TIS as follows:
    (i) Accomplish Part I (A2), paragraphs 1 through 3 of BHTI ASB 
204B-98-50, dated October 22, 1998.
    (ii) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (iii) After inspection, accomplish Part I (A2), paragraphs 5 and 
6 of BHTI ASB 204B-98-50, dated October 22, 1998.
    (3) Within 25 hours TIS, modify and inspect the vertical fin as 
follows:
    (i) Accomplish Part I (C1), paragraph 1 of BHTI ASB 204B-98-50, 
dated October 22, 1998.
    (ii) Remove sufficient rivets from the bottom row of the forward 
left-hand fin skin to allow trimming of the forward left-hand fin 
skin along the ``skin cutline'', approximately fin station 64.31 
(see Figure 2 of BHTI ASB 204B-98-50, dated October 22, 1998).
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. An existing 
edge distance less than 1.5 times the diameter of the drill or 
reamed hole must have FAA approval of the reworked area before 
proceeding.
    (iv) Accomplish Part I (C1), paragraphs 3, 4, and 6 of BHTI ASB 
204B-98-50, dated October 22, 1998.
    (v) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (vi) Accomplish Part I (C1), paragraphs 10 through 14 of BHTI 
ASB 204B-98-50, dated October 22, 1998.
    (4) After the initial modification and dye-penetrant inspection 
of the fin spar, thereafter at intervals not to exceed 300 hours 
TIS, inspect the fin spar as follows:
    (i) Accomplish Part I (C2), paragraphs 1, 2, 3, 4, 5, and 7 of 
BHTI ASB 204B-98-50, dated October 22, 1998.
    (ii) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (iii) Accomplish Part I (C2), paragraphs 11 through 14 of BHTI 
ASB 204B-98-50, dated October 22, 1998.
    (5) Within 25 hours TIS, and thereafter at intervals not to 
exceed 300 hours TIS, inspect the fin spar as follows:
    (i) Accomplish Part I (B), paragraphs 1 through 13 of BHTI ASB 
204B-98-50, dated October 22, 1998.
    (ii) Repair any disbonding discovered during the inspection 
before further flight.
    (6) Within 12 calendar months, remove fin spar P/N 205-030-899-
001, or -089, or P/N 205-030-846-001, -003, -047, or -049, or P/N 
204-030-825-063, or -065. Replace it with an airworthy fin spar 
configuration that has been demonstrated to the FAA to satisfy the 
structural fatigue requirements of repeated high torque events and 
is approved by the Manager, Rotorcraft Standards Staff.
    (7) Installation of a replacement fin spar approved by the 
Manger, Rotorcraft Standards Staff, constitutes a terminating action 
for the requirements of this AD.
    (b) For Model 205A and 205A-1 helicopters:
    (1) Within 8 hours TIS, modify the vertical fin and visually 
inspect the fin spar for cracks in accordance with Part I (A1), 
paragraphs 1 through 5 of BHTI ASB 205-98-71, Revision A, dated 
September 21, 1998.
    (i) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (ii) After inspection, apply MIL-PRF-81352 TYI clear lacquer or 
equivalent to the inside of the two lower rivet holes and on the 
surface where paint and primer were removed. Spray, brush, or wipe 
on a protective coat of MIL-C-16173, Grade 2, or equivalent, over 
the clear lacquer. To facilitate subsequent inspections do not 
replace the two lower rivets. See figure 2 of BHTI ASB 205-98-71, 
Revision A, dated September 21, 1998.
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. An existing 
edge distance less than 1.5 times the diameter of the drill or 
reamed hole must have FAA approval of the reworked area before 
proceeding.
    (iv) Fasten the forward left-hand fin skin and the retainer, P/N 
205-032-851-045, to the fin spar assembly using Hi-Loks and blind 
rivets as specified in Figure 2 of BHTI ASB 205-98-71, Revision A, 
dated September 21, 1998. Reinstall clip and radius block (if 
existing) removed in paragraph 2 of Part 1 (A1) of BHTI ASB 205-98-
71, Revision A, dated September 21, 1998.
    (v) Refinish the reworked area.
    (2) After initial modification and inspection of the vertical 
fin, thereafter, inspect the fin spar for cracks at intervals not to 
exceed 8 hours TIS as follows:
    (i) Accomplish Part I (A2), paragraphs 1 through 3 of BHTI ASB 
205-98-71, Revision A, dated September 21, 1998.
    (ii) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (iii) After inspection, accomplish Part I (A2), paragraphs 5 and 
6, of BHTI ASB 205-98-71, Revision A, dated September 21, 1998.
    (3) Within 25 hours TIS, modify and inspect the vertical fin as 
follows:
    (i) Accomplish Part I (C1), paragraph 1 of BHTI ASB 205-98-71, 
Revision A, dated September 21, 1998.
    (ii) Remove the clip, P/N 212-030-099-091, and radius block, P/N 
212-030-099-095, if present. Remove the retainer, P/N 205-032-851-
045, and sufficient rivets from the bottom row of the forward left-
hand fin skin to allow trimming of the forward left-hand fin skin 
along the ``skin cutline'', at approximately Fin Station 66.31 (see 
Figure 2 of BHTI ASB 205-98-71, Revision A, dated September 21, 
1998).
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. An existing 
edge distance less than 1.5 times the diameter of the drill or 
reamed hole must have FAA approval of the reworked area before 
proceeding.
    (iv) Accomplish Part I (C1), paragraphs 3, 4, and 6 in BHTI ASB 
205-98-71, Revision A, dated September 21, 1998.
    (v) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (vi) Accomplish Part I (C1) paragraphs 10 through 14 of BHTI ASB 
205-98-71, Revision A, dated September 21, 1998.
    (4) After the initial modification and dye-penetrant inspection 
of the fin spar, thereafter, at intervals not to exceed 300 hours 
TIS, inspect the fin spar as follows:
    (i) Accomplish Part I (C2), paragraphs 1, 2, 3, 4, 5, and 7 of 
BHTI ASB 205-98-71, Revision A, dated September 21, 1998.
    (ii) If a crack is discovered on the spar, replace the fin spar 
assembly with an airworthy fin spar assembly before further flight. 
Repair any corrosion or disbonding

[[Page 43907]]

discovered during the inspection before further flight.
    (iii) Accomplish Part I (C2), paragraphs 11 through 14 of ASB 
205-98-71, Revision A, dated September 21, 1998.
    (5) Within 25 hours TIS, and thereafter at intervals not to 
exceed 300 hours TIS inspect the fin spar as follows:
    (i) Accomplish Part I (B), paragraphs 1 through 13 of BHTI ASB 
205-98-71, Revision A, dated September 21, 1998.
    (ii) Repair any disbonding discovered during the inspection 
before further flight.
    (6) Within 12 calendar months, remove fin spar, P/N 205-030-899-
001, or -089, or P/N 205-030-846-087, or -089, or P/N 205-032-851-
003, -007, or -009. Replace it with an airworthy fin spar 
configuration that has been demonstrated to the FAA to satisfy the 
structural fatigue requirements of repeated high torque events and 
is approved by the Manager, Rotorcraft Standards Staff, or replace 
it with fin spar assembly, P/N 205-530-514-103, as specified in BHTI 
ASB 205-98-73, dated September 25, 1998.
    (7) Installing fin spar, P/N 205-530-514-103, or a fin spar that 
has been approved by the Manager, Rotorcraft Standards Staff, 
constitutes terminating action for the requirements of this AD.
    (c) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, FAA, Rotorcraft Directorate, 
Rotorcraft Certification Office. Operators shall submit their 
requests through a FAA Principal Maintenance Inspector, who may 
concur or comment and then send it to the Manager, Rotorcraft 
Certification Office.

    Note 3: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Rotorcraft Certification Office.

    (d) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the helicopter to a location where 
the requirements of this AD can be accomplished.
    (e) The inspections and modifications shall be done in 
accordance with Bell Helicopter Textron, Inc. Alert Service Bulletin 
204B-98-50, dated October 22, 1998; 205-98-71, Revision A, dated 
September 21, 1998; or 205-98-73, dated September 25, 1998, as 
applicable. These incorporations by reference were approved by the 
Director of the Federal Register in accordance with 5 U.S.C. 552(a) 
and 1 CFR part 51. Copies may be obtained from Bell Helicopter 
Textron, Inc., P.O. Box 482, Fort Worth, Texas 76101, telephone 
(817) 280-3391, fax (817) 280-6466. Copies may be inspected at the 
FAA, Office of the Regional Counsel, Southwest Region, 2601 Meacham 
Blvd., Room 663, Fort Worth, Texas; or at the Office of the Federal 
Register, 800 North Capitol Street, NW., suite 700, Washington, DC.
    (f) This amendment becomes effective on September 16, 1999.

    Issued in Fort Worth, Texas, on August 4, 1999.
Henry A. Armstrong,
Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 99-20754 Filed 8-11-99; 8:45 am]
BILLING CODE 4910-13-P

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