Document ID: FAA-2006-25173-0013
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: McCauley Propeller Systems Propeller Models B5JFR36C1101/114GCA-0, et al.
Posted Date: 2009-01-21T05:00Z

[Federal Register: January 21, 2009 (Volume 74, Number 12)]
[Proposed Rules]               
[Page 3462-3465]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr21ja09-25]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2006-25173; Directorate Identifier 2006-NE-24-AD]
RIN 2120-AA64

 
Airworthiness Directives; McCauley Propeller Systems Propeller 
Models B5JFR36C1101/114GCA-0, C5JFR36C1102/L114GCA-0, B5JFR36C1103/
114HCA-0, and C5JFR36C1104/L114HCA-0

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for McCauley Propeller Systems propeller models 
B5JFR36C1101/114GCA-0, C5JFR36C1102/L114GCA-0, B5JFR36C1103/114HCA-0, 
and C5JFR36C1104/L114HCA-0. That AD currently requires initial and 
repetitive fluorescent penetrant inspections (FPI) and eddy current 
inspections (ECI) of propeller blades for cracks, and if any crack 
indications are found, removing the blade from service. That AD also 
mandates a life limit for the blades. This proposed AD would require 
the same inspections, add a visual inspection, and would further reduce 
the propeller blade life limit. This proposed AD would also require 
removing blades with more than 10,000 operating hours time-since-new 
(TSN), before further flight. This proposed AD would also require 
removal from service of all the propeller blades and the propeller hub 
if one or more propeller blades have been found cracked on a propeller 
assembly. This proposed AD would also require removing from service all 
C-5963 split retainers. This proposed AD results from 8 reports of 
propeller blades found cracked since May of 2006. We are proposing this 
AD to detect cracks in the propeller blade that could cause failure and 
separation of the propeller blade and loss of control of the airplane.

DATES: We must receive any comments on this proposed AD by March 23, 
2009.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     Federal eRulemaking Portal: Go to http://
www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 1200 New Jersey Avenue, SE., West Building Ground 
Floor, Room W12-140, Washington, DC 20590-0001.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
     Fax: (202) 493-2251.
    Contact McCauley Propeller Systems, 5800 E. Pawnee, Wichita, KS 
67218, telephone (800) 621-7767, for the service information identified 
in this proposed AD.

FOR FURTHER INFORMATION CONTACT: Jeff Janusz, Aerospace Engineer, 
Wichita Aircraft Certification Office, FAA, Small Airplane Directorate, 
1801 Airport Road, Room 100, Wichita, KS 67209; e-mail: 
jeff.janusz@faa.gov; telephone: (316) 946-4148; fax: (316) 946-4107.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2006-25173; 
Directorate Identifier 2006-NE-24-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://
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 proposed 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 proposed 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.

Discussion

    The FAA proposes to amend 14 CFR part 39 by superseding AD 2008-08-
01, Amendment 39-15453 (73 FR 19971, April 14, 2008). That AD requires 
initial and repetitive FPI and ECI of propeller blades for cracks, and 
if any crack indications are found, removing the blade from service. 
That AD also

[[Page 3463]]

mandates a life limit for the blades. That condition, if not corrected, 
could result in failure and separation of the propeller blade and loss 
of control of the airplane.

Actions Since AD 2008-08-01 Was Issued

    Since that AD was issued, propeller blades have cracked below the 
current 10,000 hour TSN life limit of the propeller blade. The cracks 
have all been found in the blade retention groove, near the ledge where 
the split retainers seat, on or near the shot peened area of the 
propeller blade retention groove. All cracked propeller blades have 
been found on propeller assemblies that are installed on Jetstream 41 
airplanes operated by South African Airlink. All propeller blades that 
have been found cracked are part number L114HCA, which are installed in 
the propeller assembly on the No. 2 (right-side) engine. This propeller 
rotates counter-clockwise when viewed from the rear, on the Jetstream 
41 airplane. To date, there have been no other field reports of the 
same condition as described above, or occurrences of propeller blade 
failure and separation attributed to this particular unsafe condition. 
We have not yet determined if the blade cracking is the result of a 
design issue, an operational issue, or a combination of the two.

Relevant Service Information

    We have reviewed and approved the technical contents of McCauley 
Propellers Alert Service Bulletin (ASB) No. ASB255A, dated October 6, 
2008. That ASB:
     Describes procedures for an FPI and ECI of propeller 
blades for cracks;
     Describes procedures for a visual inspection of the blade 
shank for a step condition;
     Reduces the propeller blade life limit to 3,500 hours TSN;
     Removes from service all the propeller blades and the 
propeller hub if one or more propeller blades have been found cracked 
on a propeller assembly; and
     Removes from service all C-5963 split retainers.

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. For that reason, we are proposing this AD, 
which would require an FPI and ECI of propeller blades for cracks, 
would visually inspect the blade shank for a step condition, and would 
reduce the propeller blade life limit to 3,500 hours TSN. This proposed 
AD would also require removing blades with more than 10,000 operating 
hours TSN, before further flight. This proposed AD would also require 
removal from service of all the propeller blades and the propeller hub 
if one or more propeller blades have been found cracked on a propeller 
assembly. This proposed AD would also require removing from service all 
C-5963 split retainers at time of next inspection. The proposed AD 
would require that you do these actions using the service information 
described previously.

Interim Action

    These actions are interim actions and we may take further 
rulemaking actions in the future.

Costs of Compliance

    We estimate that this proposed AD would affect 8 propeller 
assemblies installed on airplanes of U.S. registry. We estimate that it 
would take about 44 work-hours per propeller to perform the proposed 
required actions, and that the average labor rate is $80 per work-hour. 
Required parts would cost about $260 per propeller, if no cracks are 
found. We estimate that one propeller will fail the blade inspection 
required by this proposed AD, and the propeller replacement cost would 
be about $67,067. Prorated life lost for the propeller assembly would 
cost about $39,043 per propeller. Based on these figures, we estimate 
the total cost of the proposed AD to U.S. operators to be $370,608.

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 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. 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 regulatory evaluation of the estimated costs to 
comply with this proposed AD. See the ADDRESSES section for a location 
to examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, 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 removing Amendment 39-15453 (73 FR 
19971, April 14, 2008) and by adding a new airworthiness directive to 
read as follows:

McCauley Propeller Systems : Docket No. FAA-2006-25173; Directorate 
Identifier 2006-NE-24-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by March 23, 
2009.

Affected ADs

    (b) This AD supersedes AD 2008-08-01, Amendment 39-15453.

Applicability

    (c) This AD applies to McCauley Propeller Systems propeller 
models B5JFR36C1101/114GCA-0, C5JFR36C1102/L114GCA-0,

[[Page 3464]]

B5JFR36C1103/114HCA-0, and C5JFR36C1104/L114HCA-0. These propellers 
are installed on BAE Systems (Operations) Limited Jetstream Model 
4100 and 4101 series airplanes (Jetstream 41).

Unsafe Condition

    (d) This AD results from 8 reports of propeller blades found 
cracked since May of 2006. We are issuing this AD to detect cracks 
in the propeller blade that could cause failure and separation of 
the propeller blade and 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.

Life Limit Reduction

    (f) For propeller blades with more than 10,000 operating hours 
time-since-new (TSN) on the effective date of this AD, remove the 
propeller blades before further flight.
    (g) For propeller blades with more than 3,000 operating hours 
TSN on the effective date of this AD, remove the propeller blades 
within the next 500 operating hours.
    (h) For propeller blades with 3,000 or fewer operating hours TSN 
on the effective date of this AD, remove the propeller blades upon 
reaching 3,500 operating hours TSN.

Removal From Service of Propeller Blades and Hubs From Propeller 
Assemblies That Already Had One or More Cracked Propeller Blades

    (i) Remove the serial number (SN) propeller blades and the hubs 
listed in Table 1 of this AD from service, using the inspection 
compliance schedule in Table 2 of this AD. These blades and hubs 
were installed on propeller assemblies that already had one or more 
propeller blades removed due to cracking, but at that time those 
blades and hubs were not required to be removed from service. Table 
1 only represents propeller assemblies that were reported to have 
cracked blades. There may be other propeller assemblies affected 
that we have not received reports on.

 Table 1--Propeller Blade and Hub SNs Requiring Removal From Service at
                             Next Inspection
------------------------------------------------------------------------
              Hub SN                              Blade SNs
------------------------------------------------------------------------
023062............................  XH31043, XH31131, XE31002, XH31025,
                                     XI31014.
040296............................  YA31058, YA31055, YB31084, YB31088,
                                     YB31090.
041016............................  XB31009, XB31073, XA31071, XA31063,
                                     WK31013.
051193............................  XH31018, XH31077, XH31081, XL31008,
                                     XL31043.
040282............................  XG31015, XG31016, XH31113, XH31117,
                                     XI31017.
051204............................  XI31049, XH31140, XH31129, XH31084,
                                     XH31074.
051194............................  WF31010, WD31032, WF31002, WF31029,
                                     WF31078.
------------------------------------------------------------------------

Propeller Blade Inspection

    (j) Perform a fluorescent penetrant inspection and eddy current 
inspection of the propeller blades, and a visual inspection for 
``step condition'' of the blade shank. Use the Equipment Required 
and Accomplishment Instructions of McCauley Propellers Alert Service 
Bulletin (ASB) No. ASB255A, dated October 6, 2008, and the 
compliance schedule in Table 2 of this AD:

                 Table 2--Inspection Compliance Schedule
------------------------------------------------------------------------
  If on the effective date of this AD,      Then inspect the propeller
          the propeller blade:                        blade:
------------------------------------------------------------------------
(1) Has more than 2,400 operating hours  Upon reaching 2,500 operating
 TSN, time-since-last inspection          hours TSLI. See TSLI
 (TSLI), or time-since-overhaul (TSO)     definition paragraph (o) of
 and has been inspected using AD 2008-    this AD.
 08-01 or McCauley Propellers ASB No.
 ASB255, dated January 8, 2007 within
 the past 2,400 operating hours.
(2) Has more than 2,400 operating hours  Within the next 100 operating
 TSN, TSLI, or TSO and has not been       hours time-in-service.
 inspected using AD 2008-08-01 or
 McCauley Propellers ASB No. ASB255,
 dated January 8, 2007 within the past
 2,400 operating hours.
(3) Has 2,400 or fewer operating hours   Upon reaching 2,500 operating
 TSN, TSLI, or TSO.                       hours TSN, TSLI, or TSO.
------------------------------------------------------------------------

Propellers Failing Blade Inspection

    (k) Remove from service all of the propeller blades, and the 
propeller hub, if one or more propeller blades are found cracked on 
a propeller assembly. Propeller blades and the propeller hub of a 
propeller assembly that has one or more cracked propeller blades, 
are no longer eligible for installation in any configuration. Do not 
install them in any configuration on any airframe.
    (l) Remove from service all propeller blades that exhibit a 
blade shank ``step condition'' of 0.005-inch or greater. Blades 
removed from service are no longer eligible for installation in any 
configuration. Do not install them in any configuration on any 
airframe.

Removal of C-5963 Split Retainers From Service

    (m) Remove from service all C-5963 split retainers at the time 
of blade inspection specified in paragraph (i) of this AD. C-5963 
split retainers removed from service are no longer eligible for 
installation in any configuration. Do not install them in any 
configuration on any airframe.
    (n) After the effective date of this AD, propeller assemblies 
with C-5963 split retainers, are prohibited from installation on any 
airframe.

Definition

    (o) For the purpose of this AD, TSLI refers only to inspections 
performed using AD 2008-08-01 or McCauley ASB No. ASB255, dated 
January 8, 2007.

Reporting Requirements

    (p) Within 10 calendar days of the inspection, use the Reporting 
Form in McCauley ASB No. ASB255A, to report all inspection findings 
to the FAA, Wichita Aircraft Certification Office, 1801 Airport 
Road, Room 100, Wichita, KS 67209, Attention: Jeff Janusz; telephone 
(316) 946-4148; fax (316) 946-4107; e-mail: jeff.janusz@faa.gov.
    (q) Include any photographs, and any other information related 
to the means of detection of the crack, and the history of the 
propeller and blades.
    (r) The Office of Management and Budget (OMB) has approved the 
reporting requirements and assigned OMB control number 2120-0056.

Alternative Methods of Compliance

    (s) The Manager, Wichita 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

    (t) Under 39.23, we are limiting the availability of special 
flight permits for this AD. Special flight permits are available 
only if:
    (1) The operator has not seen signs of external oil leakage from 
the hub; and
    (2) The operator has not observed abnormal propeller vibration 
or abnormal engine vibration; and
    (3) The operator has not observed any other abnormal operation 
from the propeller; and
    (4) The operator has not made earlier reports of abnormal 
propeller vibration, abnormal engine vibration, or other abnormal 
propeller operations that have not been addressed.

[[Page 3465]]

Related Information

    (u) Contact Jeff Janusz, Aerospace Engineer, Wichita Aircraft 
Certification Office, FAA, Small Airplane Directorate, 1801 Airport 
Road, Room 100, Wichita, KS 67209; e-mail: jeff.janusz@faa.gov; 
telephone: (316) 946-4148; fax: (316) 946-4107, for more information 
about this AD.

    Issued in Burlington, Massachusetts, on January 12, 2009.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E9-1028 Filed 1-16-09; 8:45 am]

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