[Federal Register Volume 69, Number 249 (Wednesday, December 29, 2004)]
[Proposed Rules]
[Pages 77961-77965]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-28492]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2004-19955; Directorate Identifier 2004-NE-17-AD]
RIN 2120-AA64


Airworthiness Directives; Hartzell Propeller Inc. Propellers

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for certain Hartzell Propeller Inc. propellers. This proposed AD would 
require inspecting the propeller blades and other critical propeller 
parts for corrosion and mechanical damage. This proposed AD results 
from two events where a ``Z-shank'' blade failed and separated and the 
results of teardown inspections that detected corrosion in the blade 
bore. We are proposing this AD to detect corrosion and mechanical 
damage that can cause failure of a propeller, which could result in 
loss of control of the airplane.

DATES: We must receive any comments on this proposed AD by February 28, 
2005.

ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD.
     DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street, SW., Nassif Building, Room PL-401, 
Washington, DC 20590-001.
     Fax: (202) 493-2251.

[[Page 77962]]

     Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street, SW., Washington, DC, between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    You can get the service information identified in this proposed AD 
from Hartzell Propeller Inc. Technical Publications Department, One 
Propeller Place, Piqua, OH 45356; telephone (937) 778-4200; fax (937) 
778-4391.
    You may examine the comments on this proposed AD in the AD docket 
on the Internet at http://dms.dot.gov.

FOR FURTHER INFORMATION CONTACT: Tomaso DiPaolo, Aerospace Engineer, 
Chicago Aircraft Certification Office, FAA, Small Airplane Directorate, 
2300 East Devon Avenue, Des Plaines, IL 60018-4696; telephone (847) 
294-7031; fax (847) 294-7834.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2004-19955; 
Directorate Identifier 2004-NE-17-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the proposed AD. We will 
consider all comments received by the closing date and may amend the 
proposed AD in light of those comments.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this proposed AD. Using the search function of the 
DMS Web site, anyone can find and read the comments in any of our 
dockets, including 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) or you 
may visit http://dms.dot.gov.

Examining the AD Docket

    You may examine the docket that contains the proposal, any comments 
received, and any final disposition in person at the DMS Docket Offices 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The Docket Office (telephone (800) 647-5227) is located on 
the plaza level of the Department of Transportation Nassif Building at 
the street address stated in ADDRESSES. Comments will be available in 
the AD docket shortly after the DMS receives them.

Discussion

    On January 25, 2003, a Beech 95 airplane lost control after takeoff 
when a 2.5-foot section of a Hartzell HC-92ZK-2/8447 propeller blade 
separated. Examination of the fracture surfaces revealed the blade 
failed because of fatigue cracking. The cracking began at corrosion 
pits on the internal surface of the blade bore. On July 23, 2001, a 
Beech 95A airplane suffered severe engine damage after a Hartzell HC-
92ZK-2B/8447 blade separated. Examination of the fracture surfaces 
revealed the blade failed from fatigue cracks that started in an area 
that had scratches and a gouge on the internal surface of the blade 
bore.
    The ``Z'' shank design propellers are often installed on airplanes 
that do not have a mandatory periodic propeller maintenance program and 
as a result, some propellers have not been maintained as specified in 
the manufacturers instructions. Many of the propeller models have been 
in service for more than 40 years. If they are not serviced to a recent 
maintenance document, like that required by Hartzell Service Bulletin 
136, revisions G, H, or I, those propellers are likely to contain 
corrosion or mechanical damage in the blade bore.
    After the event on January 24, 2003, the National Transportation 
Safety Board (NTSB) issued a recommendation to require repetitive 
inspections on all ``Z'' shank propellers at the time-between-overhaul 
interval recommended by Hartzell Propeller Inc. Because most ``Z'' 
shank propellers are installed on airplanes that do not have mandatory 
periodic maintenance, we are proposing a onetime inspection of ``Z'' 
shank propellers. We are also proposing a onetime inspection of ``P,'' 
``R,'' and ``W'' shank propellers because of their similarities to the 
``Z'' shank propellers. This condition, if not corrected, could result 
in failure and separation of a propeller blade, which could result in 
loss of control of the airplane. In addition, while the propeller is 
disassembled for the blade bore inspection, we are taking this 
significant opportunity to also inspect and remove corrosion and 
damaged areas in other critical propeller parts.
    We are also proposing requirement to report the inspection 
findings. The affected propellers are aging and there is no regulatory 
requirement for any type of repetitive safety inspections. We have been 
reviewing service difficulty information gathered over the past ten 
years and have received reports of ``old'' propellers (some over forty 
years of age), which have not had an overhaul, that are corroded, 
cracked, or beyond airworthy limits.

Relevant Service Information

    We have reviewed and approved the technical contents of Hartzell 
Propeller Inc. Service Bulletin (SB) 136, Revision G, dated November 
15, 1991; Revision H, dated March 12, 1993; and Revision I, dated April 
25, 2003. Those SBs describe procedures for disassembling, cleaning, 
inspecting, and reworking the propeller blades. We have also reviewed 
the applicable Hartzell overhaul manuals that we reference for the 
various additional inspections.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design. We are proposing this AD, which would require 
a onetime inspection of the bore of the propeller blade and other 
critical propeller parts, and if necessary, removing any corrosion or 
mechanical damage:
     Within 12 months after the effective date of the proposed 
AD, if the propeller was not overhauled within the past 25 years.
     Within 18 months after the effective date of the proposed 
AD, if the propeller was not overhauled within the past 20 years.
     Within 24 months after the effective date of the proposed 
AD, if the propeller was not overhauled within the past 15 years.
     Within 36 months after the effective date of the proposed 
AD, if the propeller was not overhauled within the past 10 years.
    The proposed AD would require you to use the service information 
described previously to perform these actions.

Costs of Compliance

    There are about 1,700 Hartzell propeller assemblies of the affected 
design in the worldwide fleet. We estimate that 1,200 propeller 
assemblies installed on airplanes of U.S. registry would be affected by 
this proposed AD. We also estimate that it would take about 20 work 
hours per propeller assembly to perform the proposed actions, and that 
the average labor rate is $65 per work hour. Required parts would cost 
about $450 per propeller assembly. Based on these figures, we

[[Page 77963]]

estimate the total cost of the proposed AD to U.S. operators to be 
$2,100,000.

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 proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would 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 the proposed 
regulation:
    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. Would 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 proposal 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, Safety.

The Proposed Amendment

    Under the authority delegated to me by the Administrator, the 
Federal Aviation Administration proposes to amend 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. The FAA amends Sec.  39.13 by adding the following new 
airworthiness directive:

Hartzell Propeller, Inc.: Docket No. FAA-2004-19955; Directorate 
Identifier 2004-NE-17-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by February 28, 
2005.

Affected ADs

    (b) None.
    Applicability: (c) This AD applies to Hartzell propeller 
assemblies with hub model part number (P/N) series specified in 
Table 1 of this AD. These propellers are installed on, but not 
limited to, the aircraft listed in Table 2 of this AD.

   Table 1.--List of Applicable Propeller Assemblies by Hub Model P/N
                                 Series
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HC-92W Series.
BHC-92W Series.
HC-92Z Series.
BHC-92Z Series.
HC-B3P Series.
HC-B3R Series.
HC-B3W Series.
BHC-B3W Series.
HA-B3Z Series.
HC-B3Z Series.
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    Table 2.--List of Airplanes That Might Use an Affected Propeller
                                Assembly
------------------------------------------------------------------------
      Aircraft manufacturer                    Aircraft model
------------------------------------------------------------------------
AERMACCHI (AERONAUTICA MACCHI)...  AM-3C
AERO COMMANDER...................  560-F680, 680E, 680F, 680FL, 680FLP,
                                    720
AEROSPATIALE (MORANE SAULNIER)...  733
AEROSTAR AIRCRAFT CORP...........  360
AEROTEK II, INC. (CALLAIR).......  B1A (CALLAIR)
AIR & SPACE......................  18, 18A
BEECH............................  18 Series
                                   C45
                                   35 Series
                                   A65, 65, 65-80, 65-A80, 65-B80, 65-88
                                   95, B95, B95A, D95A, E95 70
                                   C18S [(C-45(A, F), UC-45(B, F), AT-7
                                    (A, B, C), JRB-(1, 2, 3, 4), SNB-
                                    2(C)]
                                   C18S, AT-11
                                   C-45G,C-45H; TC-45G,H,J; RC-45J
                                   D18S,E18S, G18S, H18; 3N, 3NM, 3TM
                                   E50, F50, G50, H50, J50
BUSHMASTER AIRCRAFT CORP.........  BUSHMASTER 2000
CESSNA...........................  172
                                   175, 175A
                                   190, 195, A, B
                                   421, 421A
                                   A185E, A185F (SEAPLANES ONLY)
CESSNA...........................  T50
DE HAVILLAND CANADA..............  DHC-2 MKI
DORNIER..........................  DO28D, DO28D-1
FOUND BROTHERS...................  100
FOUND BROTHERS...................  FBA-2C
GOODYEAR (LOCKHEED MARTIN).......  GZ20, GZ20A
GRUMMAN (GULFSTREAM AERO.).......  G44, G44A
GRUMMAN (MCKINNON)...............  G21A

[[Page 77964]]

 
HELIO............................  H-250
                                   H-295, HT-295 (U-10D)
                                   H-395 (L-28A, U-10B)
                                   H-500
ICA (ROMANIA)....................  IAR-831
JOBMASTER........................  DGA-15P
KWAD.............................  SUPER-V
LAKE (REVO)......................  LA-4
LOCKHEED.........................  12A
MESSERSCHMITT....................  207
MOONEY...........................  M20A
NAVY.............................  N3N-3
NORD.............................  3400, 3402
PACIFIC AEROSPACE (FLETCHER).....  FU-24, FU-24A
PIAGGIO..........................  P-166B, C
PILATUS..........................  PC-6/350; PC-6/350-H1, -H2
PIPER............................  PA-23
                                   PA-24
                                   PA-25
PROCAER..........................  F15/B
REVO (COLONIAL)..................  C-2
SAAB.............................  91D SAFIR
SCHWEIZER (GRUMMAN)..............  G-164
SIMMERING GRAZ PAUKER A.G........  SGP222
SPARTON..........................  7W
UTVA.............................  66
WDL AVIATION (formerly WDL         An Airship
 FLUGDIENST).
WEATHERLY........................  201B, 201C, 620, 620A, 620C
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from two events where a ``Z-shank'' blade 
failed and separated and the results of teardown inspections that 
detected corrosion in the blade bore. We are issuing this AD to 
detect corrosion and mechanical damage that can cause failure of a 
propeller, which could result in loss of control of the airplane.
    Compliance: (e) You are responsible for having the actions 
required by this AD performed within the compliance times specified 
unless the actions have already been done.

Aircraft With Experimental Type Certificates

    (f) We recommend that you comply with the inspection 
requirements of this AD, if you have an aircraft with an 
experimental type certificate, and you have a propeller hub model 
listed in this AD installed on that aircraft.

Inspection of the Propeller

    (g) If the time-since-overhaul (TSO) of the propeller is 10 
years or fewer on the effective date of this AD, no further action 
is required.
    (h) If the propeller assembly was inspected using Hartzell 
Service Bulletin (SB) No. 136, Revision I, dated April 25, 2003; 
Revision H, dated March 12, 1993; or Revision G, dated November 15, 
1991; no further action is required.
    (i) If the TSO of the propeller assembly is more than 10 years 
on the effective date of this AD, or if the TSO is unknown, or if 
the propeller has not complied with Hartzell SBs HC-SB-61-136, 
Revision I, dated April 25, 2003; or Service Bulletin 136, Revision 
H, dated March 12, 1993; or Revision G, dated November 15, 1991; 
perform the actions specified in Table 3 of this AD. Use the 
compliance times specified in Table 3 of this AD. Information on 
inspecting the propeller assembly for cracks, corrosion or pits, 
nicks, scratches, wear, blade minimum dimensions, and damage in the 
blade balance bore can be found in the applicable Hartzell overhaul 
manual.

            Table 3.--Compliance Times for Onetime Inspection
------------------------------------------------------------------------
 If the TSO of the propeller
  assembly on the effective        Then . . .            Perform the
  date of this AD is . . .                            inspection . . .
------------------------------------------------------------------------
(1) More than 25 years or     (a) Disassemble and   Within 12 months
 the TSO is not known.         clean the propeller   after the effective
                               assembly..            date of this AD.
                              (b) Inspect for
                               cracks, corrosion
                               or pits, nicks,
                               scratches, wear,
                               blade minimum
                               dimensions, and
                               damage in the blade
                               balance hole..
                              (c) Inspect and
                               rework the
                               propeller blade
                               bore. Use 3.A. of
                               the Accomplishment
                               instructions of
                               Hartzell SB No.
                               136, Revision I,
                               dated April 26,
                               2003.
                              (d) Repair and
                               replace with
                               serviceable parts,
                               as necessary.
                              (e) Reassemble and
                               test.

[[Page 77965]]

 
(2) Twenty-one to 25 years..  (a) Disassemble and   Within 18 months
                               clean the propeller   after the effective
                               assembly.             date of this AD.
                              (b) Inspect for
                               cracks, corrosion
                               or pits, nicks,
                               scratches, wear,
                               blade minimum
                               dimensions, and
                               damage in the blade
                               balance hole..
                              (c) Inspect and
                               rework the
                               propeller blade
                               bore. Use 3.A. of
                               the Accomplishment
                               instructions of
                               Hartzell SB No.
                               136, Revision I,
                               dated April 26,
                               2003.
                              (d) Repair and
                               replace with
                               serviceable parts,
                               as necessary.
                              (e) Reassemble and
                               test.
(3) Sixteen to 20 years.....  (a) Disassemble and   Within 24 months
                               clean the propeller   after the effective
                               assembly.             date of this AD.
                              (b) Inspect for
                               cracks, corrosion
                               or pits, nicks,
                               scratches, wear,
                               blade minimum
                               dimensions, and
                               damage in the blade
                               balance hole..
                              (c) Inspect and
                               rework the
                               propeller blade
                               bore. Use 3.A. of
                               the Accomplishment
                               instructions of
                               Hartzell SB No.
                               136, Revision I,
                               dated April 26,
                               2003.
                              (d) Repair and
                               replace with
                               serviceable parts,
                               as necessary.
                              (e) Reassemble and
                               test.
(4) Eleven to 15 years......  (a) Disassemble and   Within 36 months
                               clean the propeller   after the effective
                               assembly..            date of this AD.
                              (b) Inspect for the
                               following
                               conditions: cracks,
                               corrosion or pits,
                               nicks, scratches,
                               wear, blade minimum
                               dimensions, and
                               damage in the blade
                               balance hole..
                              (c) Inspect and
                               rework the
                               propeller blade
                               bore. Use 3.A. of
                               the Accomplishment
                               instructions of
                               Hartzell SB No.
                               136, Revision I,
                               dated April 26,
                               2003.
                              (d) Repair and
                               replace with
                               serviceable parts,
                               as necessary.
                              (e) Reassemble and
                               test.
------------------------------------------------------------------------

Propeller Overhaul

    (j) Performing an overhaul of the propeller assembly after the 
effective date of this AD constitutes compliance with the 
requirements specified in this AD. The latest applicable Overhaul 
Manual issued by Hartzell Propeller Inc. contains information on 
overhauling a propeller assembly.
    (k) The TSO only changes if you overhaul the propeller assembly 
while performing the requirements specified in this AD.

Reporting Requirements

    (l) Report inspection results to the Manager, Chicago Aircraft 
Certification Office, FAA, Small Airplane Directorate, 2300 East 
Devon Ave., Des Plaines, IL 60018, within 15 working days of the 
inspection. The Office of Management and Budget (OMB) approved the 
reporting requirements assigned OMB control number 2120-0056.

Alternative Methods of Compliance (AMOCs)

    (m) The Manager, Chicago 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.

Related Information

    (n) None.

    Issued in Burlington, Massachusetts, on December 21, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-28492 Filed 12-28-04; 8:45 am]
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