Airworthiness Directives; Kelly Aerospace Power Systems Turbochargers

[Federal Register Volume 73, Number 77 (Monday, April 21, 2008)]
[Rules and Regulations]
[Pages 21222-21225]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E8-8120]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2008-0314; Directorate Identifier 2008-NE-09-AD; 
Amendment 39-15471; AD 2008-08-17]
RIN 2120-AA64


Airworthiness Directives; Kelly Aerospace Power Systems 
Turbochargers

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 Kelly Aerospace Power Systems turbochargers. This AD requires a 
onetime visual inspection of suspect turbochargers for an excessive gap 
between the turbocharger turbine housing flange and the exhaust tube 
flange, and replacement of turbochargers that fail the gap inspection. 
This AD results from two reports of exhaust leakage occurring between 
the turbocharger turbine housing flange and the exhaust tube flange due 
to machining defects of the turbocharger turbine housing flange. We are 
issuing this AD to prevent hazardous amounts of carbon monoxide from 
entering the cabin, an increase in under-cowl temperatures hampering 
engine and accessory function, and loss of tailpipe retention, which 
could lead to an in-flight fire and loss of control of the airplane.

DATES: This AD becomes effective May 6, 2008. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of May 6, 2008.
    We must receive any comments on this AD by June 20, 2008.

ADDRESSES: Use one of the following addresses to comment on this AD:
    <bullet> Federal eRulemaking Portal: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
    <bullet> Mail: U.S. Docket Management Facility, Department of 
Transportation, 1200 New Jersey Avenue SE., West Building Ground Floor, 
Room W12-140, Washington, DC 20590-0001.
    <bullet> Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    <bullet> Fax: (202) 493-2251.
    Contact Lycoming, 652 Oliver Street, Williamsport, PA 17701; 
telephone (570) 323-6181; fax (570) 327-7101, or on the Internet at 
http://www.Lycoming.Textron.com for the Lycoming Mandatory Service 
Bulletin in this AD. Contact Kelly Aerospace Power Systems, 2500 Selma 
Highway, Montgomery, AL 36108, telephone (334) 386-5450; fax (334) 386-
5450; or on the Internet at http://www.kellyaerospace.com for the Kelly 
Aerospace Power Systems Mandatory Service Bulletins in this AD.

FOR FURTHER INFORMATION CONTACT: Kevin Brane, Aerospace Engineer, 
Atlanta Aircraft Certification Office, FAA, Small Airplane Directorate, 
One Crown Center, 1895 Phoenix Blvd., Suite 450, Atlanta, GA 30349; e-
mail: [email protected]; telephone (770) 703-6063; fax (770) 703-
6097.

SUPPLEMENTARY INFORMATION: In January 2008, Lycoming Engines notified 
us, and Kelly Aerospace Power Systems, of two reports of exhaust 
leakage occurring between the turbocharger turbine housing flange and 
the exhaust tube flange. Lycoming Engines found machining defects in 
the turbine housing exit flanges of those Kelly Aerospace Power Systems 
turbochargers. Kelly Aerospace Power Systems investigated this quality 
escape, and found that the same machining defect may exist on as many 
as 310 turbochargers. This condition, if not corrected, could result in 
hazardous amounts of carbon monoxide entering the cabin and an increase 
in under-cowl temperatures hampering engine and accessory function. 
This condition could also result in loss of tailpipe retention, which 
could lead to an in-flight fire and loss of control of the airplane.

Relevant Service Information

    We have reviewed and approved the technical contents of Lycoming 
Engines Mandatory Service Bulletin (MSB) No. 580, dated February 15, 
2008, Kelly Aerospace Power Systems MSB No. 029, dated February 1, 
2008, Kelly Aerospace Power Systems MSB No. 030, Revision A, dated 
April 1, 2008, and Kelly Aerospace Power Systems MSB No. 031, dated 
February 28, 2008. These MSBs list affected engine model numbers and 
suspect turbocharger part numbers and serial numbers.

FAA's Determination and Requirements of this AD

    The unsafe condition described previously is likely to exist or 
develop on other Kelly Aerospace Power Systems turbochargers of the 
same type design. For that reason, we are issuing this AD to prevent 
hazardous amounts

[[Page 21223]]

of carbon monoxide from entering the cabin, an increase in under-cowl 
temperatures hampering engine and accessory function, and loss of 
tailpipe retention, which could lead to an in-flight fire and loss of 
control of the airplane. This AD requires a onetime visual inspection 
of suspect turbochargers for an excessive gap between the turbocharger 
turbine housing flange and the exhaust tube flange, and replacement of 
turbochargers that fail the gap inspection. You must use the service 
information previously described to identify the suspect population of 
turbochargers affected by this AD.

FAA's Determination of the Effective Date

    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we have 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-2008-0314; 
Directorate Identifier 2008-NE-09-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://www.regulations.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 
Web site, anyone can find and read the comments in any of our dockets, 
including, if provided, 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).

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, the regulatory evaluation, 
any comments received, and other information. The street address for 
the Docket Operations office (telephone (800) 647-5527) is the same as 
the Mail address provided in the ADDRESSES section. Comments will be 
available in the AD docket shortly after receipt.

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 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

    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:

2008-08-17 Kelly Aerospace Power Systems: Amendment 39-15471. Docket 
No. FAA-2008-0314; Directorate Identifier 2008-NE-09-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective May 6, 
2008.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to the turbochargers referenced in 
paragraphs (c)(1) through (c)(15)(vi) of this AD:
    (1) Kelly Aerospace Power Systems (KAPS) turbochargers, part 
number (P/N) 409170-0001 (Lycoming P/N LW-12463), installed on 
Lycoming Engines (L)TIO-540-J2B and (L)TIO-540-J2BD engines:
    (i) With the engine serial numbers (SNs) listed in Table 1 of 
Lycoming Engines Mandatory Service Bulletin (MSB) No. 580, dated 
February 15, 2008; and
    (ii) With the turbocharger SNs listed in KAPS MSB No. 029, dated 
February 1, 2008.
    (iii) Lycoming Engines (L)TIO-540-J2B and (L)TIO-540-J2BD 
engines are installed on, but not limited to, Piper PA31-350 Navajo 
Chieftain, Piper T1020 airplanes, and Colemill Panther conversion 
airplanes using a 350 horsepower engine.
    (2) KAPS turbochargers, P/N 465930-0003 (Teledyne Continental 
Motors (TCM) P/N 641672-3), installed on TCM GTSIO-520-L and GTSIO-
520-N engines, with the turbocharger SNs listed in KAPS MSB No. 030, 
Revision A, dated April 1, 2008.
    (3) KAPS turbochargers, P/N 466412-0003 (TCM P/N 652964), 
installed on TCM TSIOL-550-A and TSIOL-550-C engines, with the 
turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 
1, 2008.
    (4) KAPS turbochargers, P/N 466412-0004, installed on RAM 
modifications only, with the turbocharger SNs listed in KAPS MSB No. 
030, Revision A, dated April 1, 2008.
    (5) KAPS turbochargers, P/N 466412-0003 (TCM P/N 652964), 
installed on Cessna 414 airplanes with a TCM TSIOL-550-A or TSIOL-
550-C engine (Supplemental Type Certificate (STC) SA7633SW), with 
the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 
April 1, 2008.
    (6) KAPS turbochargers, P/N 465930-0003 (TCM P/N 641672-3), 
installed on Cessna

[[Page 21224]]

421 Golden Eagle airplanes with a TCM GTSIO-520-L or GTSIO-52-N 
engine with the turbocharger SNs listed in KAPS MSB No. 030, 
Revision A, dated April 1, 2008.
    (7) KAPS turbochargers, P/N 465680-0004 (Cessna P/N C295001-
0202), installed on TCM TSIO-520-AF or TSIO-520-P engines, with the 
turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 
1, 2008.
    (8) KAPS turbochargers, P/N 465930-0002 (TCM P/N 641672-2), 
installed on TCM GTSIO-520-M engines, with the turbocharger SNs 
listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
    (9) KAPS turbochargers, P/N 465680-0004 (Cessna P/N C295001-
0202), installed on Cessna P210 Pressurized Centurion airplanes with 
a TCM TSIO-520-AF or TSIO-520-P engine, with the turbocharger SNs 
listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
    (10) KAPS turbochargers, P/N 465930-0002 (TCM P/N 641672-2), 
installed on Cessna 404 Titan airplanes with a TCM GTSIO-520-M 
engine, with the turbocharger SNs listed in KAPS MSB No. 030, 
Revision A, dated April 1, 2008.
    (11) KAPS overhauled turbochargers, P/N 465930-9003, installed 
on TCM GTSIO-520-L or GTSIO-520-N engines, with the turbocharger SNs 
listed in KAPS MSB No. 031, dated February 28, 2008.
    (12) KAPS overhauled turbochargers, P/N 409170-9001, installed 
on Lycoming Engines TIO-540-J2B; TIO-540-J2BD; TIO-540-N2BD, and 
LTIO-540-N2BD engines, with the turbocharger SNs listed in KAPS MSB 
No. 031, dated February 28, 2008.
    (13) KAPS overhauled turbochargers, P/N 465680-9005, installed 
on Lycoming Engines TIO-540-V2AD and TIO-540-W2A engines, with the 
turbocharger SNs listed in KAPS MSB No. 031, dated February 28, 
2008.
    (14) KAPS overhauled turbochargers, P/N 465930-9002, installed 
on TCM GTSIO-520-M engines, with the turbocharger SNs listed in KAPS 
MSB No. 031, dated February 28, 2008.
    (15) Also, the following KAPS turbochargers might have been 
overhauled or repaired by other than KAPS, that used a P/N 441977-
0023S or P/N 441977-0025S turbine housing sold as a spare part, 
through the Aviall Company. These turbine housings have the date 
code of 1006 and might have been installed between October 2006 and 
January 25, 2008. The turbocharger data plates might include 
manufacturer's information other than KAPS information, such as, 
Garrett:
    (i) P/N 409170-0001; installed on Lycoming Engines TIO-540-J2B; 
TIO-540-J2BD; TIO-540-N2BD; and LTIO versions of the noted engine 
models.
    (ii) P/N 465680-0004; installed on TCM TSIO-520-AF and TSIO-520P 
engines.
    (iii) P/N 465680-0005; installed on Lycoming Engines TIO-540-
V2AD and TIO-540-W2A engines.
    (iv) P/N 465930-0002; installed on TCM GTSIO-520-M engines.
    (v) P/N 465930-0003; installed on TCM GTSIO-520-L and GTSIO-520-
N engines.
    (vi) P/N 465448-0004; installed on TCM TSIO-520-CE engines.
    (vii) P/N 466412-0003; installed on TCM TSIOL-550-A and TSIOL-
550-C engines. (viii) P/N 466412-0004; installed on engines modified 
by RAM.

Unsafe Condition

    (d) This AD results from two reports of exhaust leakage 
occurring between the turbocharger turbine housing flange and the 
exhaust tube flange due to machining defects of the turbocharger 
turbine housing flange. We are issuing this AD to prevent hazardous 
amounts of carbon monoxide from entering the cabin, an increase in 
under-cowl temperatures hampering engine and accessory function, and 
loss of tailpipe retention, which could lead to an in-flight fire 
and loss of control of the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within 10 hours time-in-service or at the next regular 
inspection interval, whichever occurs first, unless the actions have 
already been done.

Onetime Visual Inspection of Turbocharger

    (f) Carefully remove the ``V'' band clamp from around the 
turbocharger turbine housing at the turbocharger exhaust outlet, 
taking care not to move the exhaust tube and tailpipe assembly.
    (g) Visually inspect the area that was captured by the ``V'' 
band clamp. Use a feeler gauge at the split line between the turbine 
housing flange and the exhaust tube flange all around the 
circumference.
    (h) The maximum gap must not exceed 0.005 inch.
    (i) Before further flight, replace any turbocharger that exceeds 
the 0.005 inch maximum gap, with a serviceable turbocharger.
    (j) If the maximum gap is not exceeded, metal stamp a 1/8'' 
upper case ``I'' on the side of the turbocharger discharge flange. 
Information on the stamping location can be found in the MSBs 
referenced in this AD.

Definition

    (k) For the purpose of this AD, a serviceable turbocharger is 
one that is not listed in the suspect SN lists of the Lycoming 
Engines MSB or KAPS MSBs referenced in this AD, or one that passes 
the visual inspection in this AD.

Alternative Methods of Compliance

    (l) The Manager, Atlanta 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.

Special Flight Permits

    (m) Under 39.23, we are limiting the special flight permits for 
this AD by the following condition:
    (1) A special flight permit to fly the airplane to where the 
visual inspection can be done may be issued after the operator 
verifies that the turbocharger tailpipe assembly is secure.
    (2) To verify, apply a side load and a vertical load to the 
tailpipe assembly by hand. No mechanical deflection is allowed.
    (3) After verifying that the tailpipe assembly is secure, the 
operator can apply for a special flight permit from the FAA. The FAA 
office or person approving the permit must add this condition to the 
limitations of the special flight permit.

Previous Credit

    (n) If you used Kelly Aerospace Power Systems MSB No. 030, dated 
February 15, 2008 before the effective date of this AD to identify 
the suspect population of turbochargers identified in applicability 
paragraphs (c)(2) through (c)(9) of this AD, you satisfied the 
requirements of those paragraphs in this AD.

Related Information

    (o) Contact Kevin Brane, Aerospace Engineer, Atlanta Aircraft 
Certification Office, FAA, Small Airplane Directorate, One Crown 
Center, 1895 Phoenix Blvd., Suite 450, Atlanta, GA 30349; e-mail: 
[email protected]; telephone (770) 703-6063; fax (770) 703-6097, 
for more information about this AD.

Material Incorporated by Reference

    (p) You must use the service information specified in Table 1 of 
this AD to identify the suspect population of turbochargers being 
inspected by this AD. The Director of the Federal Register approved 
the incorporation by reference of the documents listed in Table 1 of 
this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. 
Contact Lycoming, 652 Oliver Street, Williamsport, PA 17701; 
telephone (570) 323-6181; fax (570) 327-7101, or go on the Internet 
at http://www.Lycoming.Textron.com for a copy of their service 
information. Also, contact Kelly Aerospace Power Systems, 2500 Selma 
Highway, Montgomery, AL 36108, telephone (334) 386-5450; fax (334) 
386-5450, or go on the Internet at http://www.kellyaerospace.com for 
a copy of their service information. You may review copies at the 
FAA, New England Region, 12 New England Executive Park, Burlington, 
MA; 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.

                                      Table 1.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
 Mandatory Service Bulletin (MSB)
               No.                          Page                Revision                      Date
----------------------------------------------------------------------------------------------------------------
Lycoming MSB No. 580.............  ALL..................  Original............  February 15, 2008.

[[Page 21225]]

 
    Total Pages: 6
Kelly Aerospace Power Systems MSB  ALL..................  Original............  February 1, 2008.
 No. 029.
    Total Pages: 4
Kelly Aerospace Power Systems MSB  ALL..................  A...................  April 1, 2008.
 No. 030.
    Total Pages: 5
Kelly Aerospace Power Systems MSB  ALL..................  Original............  February 28, 2008.
 No. 031.
    Total Pages: 5
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    Issued in Burlington, Massachusetts, on April 10, 2008.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E8-8120 Filed 4-18-08; 8:45 am]
BILLING CODE 4910-13-P

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