[Federal Register Volume 70, Number 154 (Thursday, August 11, 2005)]
[Rules and Regulations]
[Pages 46743-46747]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-15580]



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  Federal Register / Vol. 70, No. 154 / Thursday, August 11, 2005 / 
Rules and Regulations  

[[Page 46743]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-22026; Directorate Identifier 2005-SW-05-AD; 
Amendment 39-14210; AD 2005-16-05]
RIN 2120-AA64


Airworthiness Directives; Robinson Helicopter Company Model R-22 
Series Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) for 
the specified Robinson Helicopter Company (Robinson) Model R-22 series 
helicopters that have been modified in accordance with Supplemental 
Type Certificate (STC) No. SR09189RC. This action requires inspecting 
the left-hand door and right-hand door for a crack in the door assembly 
integral frame, and replacing the door assembly if a crack is found. 
This AD also requires inspecting each door assembly to determine if the 
weather seal set is airworthy and installed properly, inspecting each 
door hinge for the proper installation of a cotter pin, and thereafter, 
at intervals not to exceed 100 hours time-in-service (TIS), inspecting 
each door assembly integral frame for a crack. This amendment is 
prompted by one accident and one incident involving Robinson Model R-22 
series helicopters. The actions specified in this AD are intended to 
prevent separation of a door window or door assembly from the 
helicopter, which could damage the tail rotor during flight and result 
in loss of control of the helicopter.

DATES: Effective August 26, 2005.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of August 26, 2005.
    Comments for inclusion in the Rules Docket must be received on or 
before October 11, 2005.

ADDRESSES: Use one of the following addresses to submit comments on 
this 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;
     Fax: (202) 493-2251; or
     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 may get the service information identified in this AD from 
Tech-Tool Plastics, Inc., 7800 Skyline Park Drive, Fort Worth, Texas 
76108; telephone: (817) 246-4694; fax: (817) 246-7402; e-mail: 
tool.com">info@tech-tool.com.

Examining the Docket

    You may examine the docket that contains the AD, any comments, and 
other information on the Internet at http://dms.dot.gov, or in person 
at the Docket Management System (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 the ADDRESSES section. Comments will be available in the AD 
docket shortly after the DMS receives them.

FOR FURTHER INFORMATION CONTACT: Marc Belhumeur, Aviation Safety 
Engineer, FAA, Rotorcraft Directorate, Rotorcraft Certification Office, 
Fort Worth, Texas 76193-0170, telephone (817) 222-5177, fax (817) 222-
5783.

SUPPLEMENTARY INFORMATION: This amendment adopts a new AD for Robinson 
Model R-22 series helicopters that have been modified with door 
assemblies manufactured by Tech-Tool Plastics, Inc., in accordance with 
STC No. SR09189RC. This action requires:
     Within 30 days, inspecting each door assembly integral 
frame for a crack, and before further flight, replacing the left-hand 
door assembly, part number (P/N) R-22-101-51 or P/N R-22-101-53, or 
right-hand door assembly, P/N R-22-101-52 or P/N R-22-101-54, if a 
crack is found;
     Within 30 days, if crack is not found on a door assembly, 
inspecting the door assembly weather seal set to determine if it is 
airworthy and installed properly, and if it is not, before further 
flight, reinstalling or replacing the weather seal set with weather 
seal set, P/N 74418x14L and P/N 74814x12BL, or with any other 
appropriate airworthy weather seal set;
     Within 30 days, if a crack is not found on a door 
assembly, inspecting to determine that a cotter pin, P/N MS24665-136, 
is installed properly in each of the two hinges on the door assembly, 
and if it is not, before further flight, properly installing the cotter 
pin;
     Thereafter, at intervals not to exceed 100 hours (TIS), 
inspecting each door assembly integral frame for a crack and replacing 
the door assembly if a crack is found; and,
     Within 30 days after discovering a crack, reporting that 
information as well as the helicopter model to the FAA. You may submit 
your report via mail, Fax, or telephone to the FAA, ATTN: ASW-170 (Marc 
Belhumeur), 2601 Meacham Blvd., Fort Worth, Texas 76137; telephone: 
(817) 222-5177; Fax: (817) 222-5783.
    This amendment is prompted by an accident on November 27, 2004, 
involving a Robinson Model R-22 Beta helicopter, which resulted in two 
fatalities. This amendment is also prompted by one incident involving a 
Robinson Model R-22 series helicopter, which was reported to Tech-Tool 
Plastics, Inc., the door assembly manufacturer, on September 20, 2004. 
A preliminary investigation of the helicopter involved in the accident 
indicated that the doors separated from the helicopter at some 
undetermined time and that the separation may have been partially due 
to the door hinge cotter pins not being installed properly. In the 
incident, an operator reported that the window in the pilot door had 
separated from the helicopter during flight at an altitude of 4,500 
feet.

[[Page 46744]]

Subsequent investigation revealed cracking across the composite door 
assembly integral frame stiffener bead, just beneath the lower hinge on 
the forward edge of the door, and at the upper and lower door cam lock 
on the trailing edge of the door. Further investigation revealed that 
the door weather seal set was not the weather seal set supplied by the 
door assembly manufacturer. Additionally, the two nylon adjustment 
screws, which are required to relieve excessive force on the door 
hinges, were broken or missing. Finally, the door may not have been 
trimmed to the cabin door opening as stated in the manufacturer's door 
assembly installation drawings. The actions specified in this AD are 
intended to prevent separation of a door window or door assembly from 
the helicopter, which could damage the tail rotor during flight and 
result in loss of control of the helicopter.
    We have reviewed Tech-Tool Plastics, Inc. Installation 
Instructions, TTP-1R, Revision A, dated November 21, 1997, which is 
part of STC SR09189RC authorizing installation of door assemblies on 
these affected helicopters. We have also reviewed Tech-Tool Plastics, 
Inc. Service Bulletin No. TTP2005-01, Revision A, dated February 1, 
2005 (SB), which describes procedures for a one-time visual inspection 
for cracks and proper installation of the door assemblies and before 
the first flight of each day recurring visual checks for cracks. The SB 
also includes weather seal set and cotter pin installation instructions 
that were inadvertently omitted from the Installation Instructions of 
TTP-1R, Revision A, dated November 21 1997. Cracks in a helicopter door 
or improper installation create an unsafe condition.
    This unsafe condition is likely to exist or develop on other 
helicopters of the same supplemental type design. Therefore, this AD is 
being issued to prevent separation of a door window or door assembly 
from the helicopter, which could damage the tail rotor during flight 
and result in loss of control of the helicopter. This AD requires 
inspecting the left-hand door and right-hand door for a crack in the 
door assembly integral frame, and replacing the door assembly if a 
crack is found. This AD also requires inspecting each door assembly to 
determine if the weather seal set is airworthy and installed properly, 
inspecting each door hinge for the proper installation of a cotter pin, 
and inspecting each door assembly integral frame for a crack at 
intervals not to exceed 100 hours TIS. Also, reporting the results of 
the inspections to the FAA is required if a crack is found. Accomplish 
the required actions in accordance with the specified portions of the 
service information described previously. The short compliance time 
involved is required because the previously described critical unsafe 
condition can adversely affect the structural integrity and 
controllability of the helicopter. Since the one-time inspections of 
each door assembly frame, cotter pins, and weather seal set are 
required within 30 days, and because each 100-hour TIS interval for 
inspecting each door assembly frame for cracking may occur within 30 
calendar days for those helicopters being used for training or other 
high usage missions, 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.
    We estimate that this AD will affect 200 helicopters of U.S. 
registry, and the actions will take approximately:
     .1 work hour to inspect for cracking in each door assembly 
integral frame;
     .1 work hour to inspect the weather seal set, and both 
cotter pins in each door assembly; and
     .5 work hour to install each door assembly.

The average labor rate is $65 per work hour. Required parts will cost 
approximately $4,464 per helicopter if replacing each door assembly and 
reinstalling and trimming each door is required. Based on these 
figures, we estimate the total cost impact of the AD on U.S. operators 
to be $1,857,400, assuming 366 inspections for cracking in each door 
assembly integral frame are accomplished, and that both door assemblies 
on all Robinson Model R-22 series helicopters are replaced.

Comments Invited

    This AD is a final rule that involves requirements that affect 
flight safety and was not preceded by notice and an opportunity for 
public comment; however, we invite you to submit any written data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-14210; 
Directorate Identifier 2005-SW-05-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the AD. We will consider 
all comments received by the closing date and may amend the 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 AD. Using the search function of our docket 
web site, you can find and read the comments to any of our dockets, 
including the name of the individual who sent the comment. 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.

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 the 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. 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 an economic evaluation of the estimated costs to comply 
with this AD. See the DMS to examine the economic evaluation.

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.

[[Page 46745]]

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
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

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. Section 39.13 is amended by adding a new airworthiness directive to 
read as follows:

2005-16-05 Robinson Helicopter Company: Amendment 39-14210. Docket 
No. FAA-2005-22026; Directorate Identifier 2005-SW-05-AD.

    Applicability: Model R-22 series helicopters, modified with a 
door assembly manufactured by Tech-Tool Plastics, Inc., in 
accordance with STC No. SR09189RC, certificated in any category.
    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent separation of a door window or door assembly from the 
helicopter, which could damage the tail rotor during flight and 
result in loss of control of the helicopter, accomplish the 
following:
    (a) Within 30 days, inspect the left-hand and right-hand door 
assemblies as follows:
    (1) Visually inspect each pilot and copilot door assembly 
integral frame for a crack in the locations depicted in Figure 1 of 
this AD. If a crack is found, before further flight, replace the 
cracked door assembly, part number (P/N) R-22-101-51 or P/N R-22-
101-53 (left-hand door assembly), or P/N R-22-101-52 or P/N R-22-
101-54 (right-hand door assembly), with an airworthy door assembly. 
If you use door assembly, P/N R-22-101-51 or P/N R-22-101-53 (left-
hand door assembly), or P/N R-22-101-52 or P/N R-22-101-54 (right-
hand door assembly) as the replacement, then install it in 
accordance with Tech-Tool Plastics, Inc. Installation Instructions 
TTP-1R, Revision A, dated November 21, 1997, and with the sections 
titled ``Door Weather Seal Installation'' and ``Cotter Pin 
Installation'' in Tech-Tool Plastics, Inc. Service Bulletin No. 
TTP2005-01, Revision A, dated February 1, 2005 (SB).

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[GRAPHIC] [TIFF OMITTED] TR11AU05.020

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[[Page 46747]]

    (2) If no crack is found in any door assembly integral frame, do 
the following:
    (i) Visually inspect the weather seal set in each door assembly 
to determine if it is airworthy and installed properly. If it is not 
airworthy, before further flight, replace it with either the weather 
seal set, P/N 74418X14L and P/N 74814X12BL, supplied by Tech-Tool 
Plastics, Inc., in accordance with the ``Door Weather Seal 
Installation'' section of the SB, or replace it with any other 
airworthy door weather seal set in accordance with the applicable 
FAA-approved installation instructions. If an airworthy weather seal 
set, P/N 74418X14L and P/N 74814X12BL, is not installed properly, 
before further flight, reinstall it in accordance with the ``Door 
Weather Seal Installation'' section of the SB. If the improperly 
installed weather seal set is not the weather seal set supplied by 
Tech-Tool Plastics, Inc., before further flight, reinstall it in 
accordance with the applicable FAA-approved installation 
instructions.
    (ii) Visually inspect each door hinge on each door assembly to 
determine if the cotter pins, P/N MS24665-136, are installed in 
accordance with the ``Cotter Pin Installation'' section of the SB. 
If a cotter pin is not installed in accordance with the ``Cotter Pin 
Installation'' section of the SB, before further flight, install the 
cotter pins in accordance with the ``Cotter Pin Installation'' 
section of the SB.

    Note: The installation of nylon adjustment screws and the 
trimming of door assembly edges are important maintenance actions 
that may reduce the strength of a door assembly if not done 
properly.

    (b) After accomplishing the inspections in paragraphs (a) 
through (a)(2)(ii) of this AD, at intervals not to exceed 100 hours 
time-in-service, visually inspect each pilot and copilot door 
assembly integral frame for a crack in the locations depicted in 
Figure 1 of this AD.
    (c) If a crack is found, before further flight, replace the 
cracked door assembly, P/N R-22-101-51 or P/N R-22-101-53 (left-hand 
door assembly), or P/N R-22-101-52 or P/N R-22-101-54 (right-hand 
door assembly), with an airworthy door assembly. If the replacement 
door assembly is P/N R-22-101-51 or P/N R-22-101-53 (left-hand door 
assembly), or P/N R-22-101-52 or P/N R-22-101-54 (right-hand door 
assembly), then install it in accordance with Tech-Tool Plastics, 
Inc. Installation Instructions TTP-1R, Revision A, dated November 
21, 1997, and ``Door Weather Seal Installation'' and ``Cotter Pin 
Installation'' sections of the SB.
    (d) If any of the inspections required by this AD reveal a crack 
in any door assembly frame, report the following information to the 
FAA within 30 days after discovering the crack: a description of the 
crack and the specific helicopter model involved. You may submit 
your report via mail, Fax, or telephone to the FAA, ATTN: ASW-170 
(Marc Belhumeur), 2601 Meacham Blvd., Fort Worth, Texas 76137, 
telephone (817) 222-5177, fax (817) 222-5783. Information collection 
requirements contained in this AD have been approved by the Office 
of Management and Budget (OMB) under the provisions of the Paperwork 
Reduction Act of 1980 (44 U.S.C. 3501 et seq.) and have been 
assigned OMB Control Number 2120-0056.
    (e) To request a different method of compliance or a different 
compliance time for this AD, follow the procedures in 14 CFR 39.19. 
Contact the Rotorcraft Certification Office, Rotorcraft Directorate, 
FAA, for information about previously approved alternative methods 
of compliance.
    (f) The inspections, repairs and replacements, if necessary, 
shall be done in accordance with the specified portions of Tech-Tool 
Plastics, Inc. Installation Instructions TTP-1R, Revision A, dated 
November 21, 1997, which provides door assembly installation 
instructions, and the specified portions of Tech-Tool Plastics, Inc. 
Service Bulletin No. TTP2005-01, Revision A, dated February 1, 2005, 
which describes door weather seal and cotter pin installation 
procedures and door assembly inspection procedures. The Director of 
the Federal Register approved this incorporation by reference in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be 
obtained from Tech-Tool Plastics, Inc., 7800 Skyline Park Drive, 
Fort Worth, Texas, 76108; telephone: (817) 246-4694; fax: (817) 246-
7402; E-mail: tool.com">info@tech-tool.com.
    (g) This amendment becomes effective on August 26, 2005.

    Issued in Fort Worth, Texas, on July 29, 2005.
S. Frances Cox,
Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 05-15580 Filed 8-10-05; 8:45 am]
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