[Federal Register Volume 63, Number 225 (Monday, November 23, 1998)]
[Rules and Regulations]
[Pages 64612-64615]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 98-31195]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 97-SW-20-AD; Amendment 39-10900; AD 98-24-15]
RIN 2120-AA64


Airworthiness Directives; Bell Helicopter Textron Model 204B, 
205A, 205A-1, 205B, and 212 Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), applicable to Bell Helicopter Textron Model 204B, 205A, 205A-1, 
and 212 helicopters, that currently establishes a retirement life for 
the main rotor masts (masts) and main rotor trunnions (trunnions) based 
on time-in-service (TIS) and types of operations. This amendment adds 
Model 205B helicopters to the applicability; requires creation of 
component history cards or equivalent records using a Retirement Index 
Number (RIN) system; establishes a system for tracking increases to the 
accumulated RIN; and establishes a maximum accumulated RIN for certain 
masts and trunnions. This amendment is prompted by an accident 
involving a Model 205A-1 helicopter, in which a mast failure caused a 
separation of the main rotor from the helicopter. The actions specified 
by this AD are intended to prevent fatigue failure of the mast or 
trunnion and subsequent loss of control of the helicopter.

DATES: Effective December 8, 1998.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of December 8, 1998.
    Comments for inclusion in the Rules Docket must be received on or 
before January 22, 1999.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Office of the Regional Counsel, Southwest Region, 
Attention: Rules Docket No. 97-SW-20-AD, 2601 Meacham Blvd., Room 663, 
Fort Worth, Texas 76137.
    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 76137; or at the Office 
of the Federal Register, 800 North Capitol Street, NW., suite 700, 
Washington, DC.

FOR FURTHER INFORMATION CONTACT: Charles C. Harrison, Aerospace 
Engineer, FAA, Rotorcraft Directorate, Rotorcraft Standards Staff, 2601 
Meacham Blvd., Fort Worth, Texas 76137, telephone (817) 222-5447, fax 
(817) 222-5960.

SUPPLEMENTARY INFORMATION: On December 28, 1988, the FAA issued AD 89-
02-07, Amendment 39-6112 (54 FR 1338, January 13, 1989) and on 
September 19, 1989, issued revised AD 89-02-07 R1, Amendment 39-6339 
(54 FR 40381, October 2, 1989), to establish a retirement life for 
certain masts and trunnions based on TIS and types of operations. Those 
actions were prompted by results of fatigue stress tests and fatigue 
analysis of the mast and trunnion under ground-air-ground (GAG) and 
repeated heavy lift (RHL) loading conditions. On June 27, 1997, the FAA 
issued priority letter AD 97-14-12 to supersede AD 89-02-07 as revised 
by AD 89-02-07 R1 to establish retirement lives for certain masts and 
trunnions that utilize a Retirement Index Number (RIN) system. 
Exceeding the retirement life of the mast or

[[Page 64613]]

trunnion could result in fatigue failure of the mast or trunnion and 
subsequent loss of control of the helicopter.
    Since the issuance of AD 89-02-07 and AD 89-02-07 R1, the 
manufacturer has issued the following service bulletins to establish 
retirement lives for certain masts and trunnions:
     Bell Helicopter Textron Alert Service Bulletin No. 205-90-
40, Revision A, dated March 21, 1991, which is applicable to Model 
205A-1 helicopters;
     Bell Helicopter Textron Alert Service Bulletin No. 205B-
90-1, Revision A, dated March 21, 1991, which is applicable to Model 
205B helicopters; and
     Bell Helicopter Textron Alert Service Bulletin No. 212-90-
64, Revision B, dated March 11, 1992, which is applicable to Model 212 
helicopters.
    Also, since the issuance of the earlier AD's, there has been one 
accident involving a Model 205A-1 helicopter, in which a mast failure 
caused a separation of the main rotor from the helicopter. The 
helicopter, which had been utilized in external load lift operations, 
was performing an external load lift operation at the time of the 
accident. A subsequent metallurgical examination revealed that the mast 
had fractured as a result of fatigue. Analyses and fatigue testing has 
confirmed that the retirement lives of the mast and trunnion are more 
accurately assessed by monitoring the number of torque events and time-
in-service (TIS) incurred by the helicopter rather than by monitoring 
only TIS. Exceeding the retirement life of the mast or trunnion could 
result in fatigue failure of the mast or trunnion and subsequent loss 
of control of the helicopter. Additionally, the FAA has determined that 
Model 205B helicopters should be added to the applicability.
    Since an unsafe condition has been identified that is likely to 
exist or develop on other Model 204B, 205A, 205A-1, 205B, and 212 
helicopters of the same type design, this AD supersedes AD 89-02-07 as 
revised by AD 89-02-07 R1 and AD 97-14-12 to require, before further 
flight, creation of component history cards or equivalent records using 
a RIN system for certain masts and trunnions; to establish a system for 
tracking increases to the accumulated RIN; and to establish retirement 
lives for the mast and trunnion for each of the affected model 
helicopters. The actions are required to be accomplished in accordance 
with the service bulletins described previously. The short compliance 
time involved is required because the previously described critical 
unsafe condition can adversely affect the structural integrity of the 
aircraft. Therefore, the actions are required before further flight, 
and this AD must be issued immediately.
    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this rule must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket No. 97-SW-20-AD.'' The postcard will be date stamped and 
returned to the commenter.
    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.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and that it is not a ``significant regulatory 
action'' under Executive Order 12866. It has been determined further 
that this action involves an emergency regulation under DOT Regulatory 
Policies and Procedures (44 FR 11034, February 26, 1979). If it is 
determined that this emergency regulation otherwise would be 
significant under DOT Regulatory Policies and Procedures, a final 
regulatory evaluation will be prepared and placed in the Rules Docket. 
A copy of it, if filed, 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 39-6112 (54 FR 
1338, January 13, 1989), Amendment 39-6339 (54 FR 40381, October 2, 
1989) and by adding a new airworthiness directive (AD), Amendment 39-
10900, to read as follows:

AD 98-24-15  Bell Helicopter Textron: Amendment 39-10900. Docket No. 
97-SW-20-AD. Supersedes AD 89-02-07, Amendment 39-6112, Docket No. 
87-ASW-63; AD 89-02-07 R1, Amendment 39-6339, Docket No. 87-ASW-63; 
and priority letter AD 97-14-12, Docket No. 97-SW-20-AD.
    Applicability: Model 204B, 205A, 205A-1, 205B, and 212 
helicopters, certificated in any category.

    Note 1: This AD applies to each helicopter identified in the 
preceding applicability provision, regardless of whether it has been 
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 use the authority

[[Page 64614]]

provided in paragraph (e) to request approval from the FAA. This 
approval may address either no action, if the current configuration 
eliminates the unsafe condition, or different actions necessary to 
address the unsafe condition described in this AD. Such a request 
should include an assessment of the effect of the changed 
configuration on the unsafe condition addressed by this AD. In no 
case does the presence of any modification, alteration, or repair 
remove any helicopter from the applicability of this AD.

    Compliance: Required before further flight, unless accomplished 
previously.
    To prevent fatigue failure of the main rotor mast (mast) or main 
rotor trunnion (trunnion), and subsequent loss of control of the 
helicopter, accomplish the following:
    (a) For Model 204B helicopters:
    (1) Create component history cards or equivalent records for the 
mast, part number (P/N) 204-011-450-001, -007, or -105 and trunnion, 
P/N 204-011-105-001.
    (2) Determine and record on the component history cards or 
equivalent records the accumulated RIN to-date on the mast and 
trunnion as follows:
    (i) For mast, P/N 204-011-450-001, multiply the total time-in-
service (TIS) on the mast to-date by 50 (if result contains a 
decimal point, round-off to the next higher whole number).
    (ii) For mast, P/N 204-011-450-007 or -105, and trunnion, P/N 
204-011-105-001, multiply the total TIS on the part to-date by 20 
(if the result contains a decimal point, round-off to the next 
higher whole number).
    (3) After complying with paragraphs (a)(1) and (a)(2) of this 
AD, during each operation thereafter, maintain a count of the number 
and type of external load lifts and the number of takeoffs that were 
performed. At the end of each day's operations, increase the 
accumulated RIN on the component history cards or equivalent records 
as follows:
    (i) Increase the RIN by 1 for each takeoff.
    (ii) Increase the RIN by 1 for each external load lift, or 
increase the RIN by 2 for each external load lift operation in which 
the load is picked up at one elevation and released at another 
elevation, and the difference in elevation between the pickup point 
and the release point is 200 feet or greater.
    (4) Remove the mast, P/N 204-011-450-001, on or before attaining 
6,000 hours TIS, or an accumulated RIN of 300,000, whichever occurs 
first.
    (5) Remove the mast, P/N 204-011-450-007 or -105, or trunnion, 
P/N 204-011-105-001, on or before attaining 15,000 hours TIS, or an 
accumulated RIN of 300,000, whichever occurs first.
    (b) For Model 205A and 205A-1 helicopters:
    (1) Create component history cards or equivalent records for the 
mast, part numbers (P/N) 204-011-450-007, or -105 and trunnion, P/N 
204-011-105-001.
    (2) Determine and record on the component history cards or 
equivalent records the accumulated RIN to-date on the mast and 
trunnion. For mast, P/N 204-011-450-007 or -105, and trunnion, P/N 
204-011-105-001, multiply the factored flight hour total to-date, 
determined in accordance with paragraphs 1, 2, or 3 of the 
Accomplishment Instructions of Bell Helicopter Textron Alert Service 
Bulletin No. 205-90-40, Revision A, dated March 21, 1991, by 20 (if 
the result contains a decimal point, round-off to the next higher 
whole number).
    (3) After complying with paragraphs (b)(1) and (b)(2) of this 
AD, during each operation thereafter, maintain a count of the number 
and type of external load lifts and the number of takeoffs that were 
performed. At the end of each day's operations, increase the 
accumulated RIN on the component history cards or equivalent records 
as follows:
    (i) Increase the RIN by 2 for each takeoff performed.
    (ii) Increase the RIN by 2 for each external load lift, or 
increase the RIN by 4 for each external load lift operation in which 
the load is picked up at one elevation and released at another 
elevation, and the difference in the elevation between the pickup 
point and the release point is 200 feet or greater.
    (4) Remove the mast, P/N 204-011-450-007 or -105, or trunnion, 
P/N 204-011-105-001, on or before attaining 15,000 hours TIS, or an 
accumulated RIN of 300,000, whichever occurs first.
    (c) For Model 205B helicopters:
    (1) Create component history cards or equivalent records for the 
mast, P/N 204-011-450-007, or -105 and trunnion, P/N 204-011-105-
001.
    (2) Determine and record on the component history cards or 
equivalent records the accumulated RIN to-date on the mast and 
trunnion. For mast, P/N 204-011-450-007 or -105, and trunnion, P/N 
204-011-105-001, multiply the factored flight hour total to-date, 
determined in accordance with paragraph 1, 2, or 3 of the 
Accomplishment Instructions of Bell Helicopter Textron Alert Service 
Bulletin No. 205B-90-1, Revision A, dated March 21, 1991, by 20 (if 
the result contains a decimal point, round-off to the next higher 
whole number).
    (3) After complying with paragraphs (c)(1) and (c)(2) of this 
AD, during each operation thereafter, maintain a count of the number 
and type of external load lifts and the number of takeoffs 
performed, and at the end of each day's operations, increase the 
accumulated RIN on the component history card as follows:
    (i) Increase the RIN by 5 for each takeoff performed.
    (ii) Increase the RIN by 5 for each external load lift, or 
increase the RIN by 10 for each external load lift in which the load 
is picked up at one elevation and released at another elevation, and 
the difference in the elevation between the pickup point and the 
release point is 200 feet or greater.
    (4) Remove the mast, P/N 204-011-450-007 or -105, or trunnion, 
P/N 204-011-105-001, on or before attaining 15,000 hours TIS, or an 
accumulated RIN of 300,000, whichever occurs first.
    (d) For Model 212 helicopters:
    (1) Create component history cards or equivalent records for the 
mast, P/N 204-011-450-007, -105, -113, or -119 and trunnion, P/N 
204-011-105-001 or -103.
    (2) Determine and record on the component history card or an 
equivalent record the accumulated RIN to-date on the mast and 
trunnion as follows:
    (i) For mast, P/N 204-011-450-007 or -105, and trunnion, P/N 
204-011-105-001, multiply the factored flight hour total to-date, 
determined in accordance with paragraphs 1, 2, and 3 of the 
Accomplishment Instructions of Bell Helicopter Textron Alert Service 
Bulletin No. 212-90-64, Revision B, dated March 11, 1992, by 20 (if 
the result contains a decimal point, round-off to the next higher 
whole number).
    (ii) For mast, P/N 204-011-450-113 or -119, and trunnion, P/N 
204-011-105-103, multiply the factored flight hour total to-date, 
determined in accordance with paragraphs 1, 2, or 3 of the 
Accomplishment Instructions in Bell Helicopter Textron Alert Service 
Bulletin No. 212-90-64, Revision B, dated March 11, 1992, by 21.2 
(if the result contains a decimal point, round-off to the next 
higher whole number).
    (3) After complying with paragraphs (d)(1) and (d)(2) of this 
AD, during each operation thereafter, maintain a count of the number 
and type of external load lifts and the number of takeoffs 
performed. At the end of each day's operations, increase the 
accumulated RIN on the component history cards or equivalent records 
as follows:
    (i) Increase the RIN by 5 for each takeoff performed.
    (ii) Increase the RIN by 5 for each external load lift, or 
increase the RIN by 10 for each external load lift in which the load 
is picked up at one elevation and released at another elevation, and 
the difference in the elevation between the pickup point and the 
release point is 200 feet or greater.
    (4) Remove the mast, P/N 204-011-450-007 or -105, or trunnion, 
P/N 204-011-105-001, on or before attaining 15,000 hours TIS, or an 
accumulated RIN of 300,000, whichever occurs first.
    (5) Remove the mast, P/N 204-011-450-113 or -119, or trunnion, 
P/N 204-011-105-103, on or before attaining 13,000 hours TIS or an 
accumulated RIN of 275,000, whichever occurs first.
    (e) 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, Rotorcraft Standards Staff, 
Rotorcraft Directorate, FAA. Operators shall submit their requests 
through an FAA Principal Maintenance Inspector, who may concur or 
comment and then send it to the Manager, Rotorcraft Standards Staff.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Rotorcraft Standards Staff.

    (f) 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.
    (g) This AD revises the Airworthiness Limitations sections of 
the maintenance manuals by establishing a new retirement life for 
the affected masts and trunnions as follows:
    Masts: P/N 204-011-450-001--6,000 hours TIS or 300,000 RIN 
whichever occurs first.

[[Page 64615]]

    P/N 204-011-450-007 or P/N 204-011-450-105--15,000 hours TIS or 
300,000 RIN, whichever occurs first.
    P/N 204-011-450-113 or P/N 204-011-450-119--13,000 hours TIS or 
275,000 RIN, whichever occurs first.
    Trunnions: P/N 204-011-105-001--15,000 hours TIS or 300,000 RIN, 
whichever occurs first.
    P/N 204-011-105-103--13,000 hours TIS or 275,000 RIN, whichever 
occurs first.
    (h) The actions shall be done in accordance with:
     Bell Helicopter Textron Alert Service Bulletin No. 205-
90-40, Revision A, dated March 21, 1991, which is applicable to 
Model 205A and 205A-1 helicopters;
     Bell Helicopter Textron Alert Service Bulletin No. 
205B-90-1, Revision A, dated March 21, 1991, which is applicable to 
Model 205B helicopters; and
     Bell Helicopter Textron Alert Service Bulletin No. 212-
90-64, Revision B, dated March 11, 1992, which is applicable to 
Model 212 helicopters.
    This incorporation by reference was 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.
    (i) This amendment becomes effective on December 8, 1998.

    Issued in Fort Worth, Texas, on November 13, 1998.
Henry A. Armstrong,
Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 98-31195 Filed 11-20-98; 8:45 am]
BILLING CODE 4910-13-P