Document ID: FAA-2007-0051-0040
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Continental Motors, Inc. Reciprocating Engines with Superior Air Parts, Inc. (SAP) Cylinder Assemblies Installed
Posted Date: 2013-09-13T04:00Z

[Federal Register Volume 78, Number 178 (Friday, September 13, 2013)]
[Proposed Rules]
[Pages 56622-56625]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2013-22273]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-0051; Directorate Identifier 2007-NE-37-AD]
RIN 2120-AA64

Airworthiness Directives; Continental Motors, Inc. Reciprocating 
Engines With Superior Air Parts, Inc. (SAP) Cylinder Assemblies 
Installed

AGENCY: Federal Aviation Administration (FAA), DOT.

[[Page 56623]]

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to supersede an existing airworthiness directive 
(AD) that applies to certain Continental Motors, Inc. (CMI) IO-520, 
TSIO-520, and IO-550 series reciprocating engines, with certain 
replacement parts manufacturer approval (PMA) SAP investment cast 
cylinder assemblies installed. The existing AD currently requires 
initial and repetitive inspections and compression tests to detect 
cracks in those cylinders. Since we issued that AD, we became aware of 
additional engines that need to be added to the applicability. We are 
proposing this AD to prevent the separation of the cylinder head, 
damage to the engine, and damage to the airplane.

DATES: We must receive comments on this proposed AD by November 12, 
2013.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this AD, contact Continental 
Motors, Inc., 2039 Broad St., Mobile, AL 36615; phone: 251-438-3411; 
Web site: http://www.continentalmotors.aero/Support_Materials/Publications/Service_Bulletins/. You may view this service information 
at the FAA, Engine & Propeller Directorate, 12 New England Executive 
Park, Burlington, MA. For information on the availability of this 
material at the FAA, call 781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Management Facility 
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 Office (phone: 800-647-5527) is in the ADDRESSES 
section. Comments will be available in the AD docket shortly after 
receipt.

FOR FURTHER INFORMATION CONTACT: Peter W. Hakala, Aerospace Engineer, 
Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76193; phone: 817-222-5145; fax: 817-222-5785; 
email: peter.w.hakala@faa.gov.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposed AD. Send your comments to an address 
listed under the ADDRESSES section. Include ``Docket No. FAA-2007-0051; 
Directorate Identifier 2007-NE-37-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this proposed AD. We 
will consider all comments received by the closing date and may amend 
this proposed AD because 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 we 
receive about this proposed AD.

Discussion

    On July 23, 2009, we issued AD 2009-16-03, Amendment 39-15986 (74 
FR 38896, August 5, 2009), for certain Teledyne Continental Motors 
reciprocating engines with certain replacement PMA part numbers (P/Ns) 
of SAP cylinder assemblies installed. That AD requires initial and 
repetitive inspections and compression tests to detect cracks in those 
cylinders, with more than 750 flight hours time-in-service. That AD 
resulted from reports of cracks in the area of the exhaust valve and 
separation of cylinder heads from the barrels of SAP cylinder 
assemblies with certain P/Ns. We issued that AD to prevent the 
separation of the cylinder head, damage to the engine, and damage to 
the airplane.

Actions Since Existing AD Was Issued

    Since we issued AD 2009-16-03 (74 FR 38896, August 5, 2009), we 
became aware of supplemental type certificates (STCs) that modify CMI 
470 series engines to accept CMI 520 or 550 cylinders. Those modified 
CMI 470 series engines could also have the affected P/Ns SAP cylinders 
installed. Therefore, those additional engines may suffer from the same 
unsafe condition that AD 2009-16-03 addresses.
    We also changed the format for applicability from listing the 
affected models of CMI reciprocating engines in a table, to stating in 
a paragraph the affected reciprocating engine models. We made this 
change due to a comment that the AD was in error in listing the TSIO-
520 engines, and that the applicability table did not list this model. 
The TSIO-520 model engines are, in fact, affected by the AD.
    Also, since we issued AD 2009-16-03 (74 FR 38896, August 5, 2009), 
we became aware that determining the applicability of a cylinder might 
be difficult. We have added a paragraph to the proposed AD to clarify 
the identification of SAP cylinder assemblies. The paragraph expands 
what is in the existing AD by also looking for casting markings ``CP'' 
on the cylinder head. Operators can rely on the casting markings in 
determining if a cylinder assembly is affected, when the P/N on the 
bottom flange of the cylinder assembly is not visible.
    We also changed the cost of compliance because the estimated 
population of engines with the SAP investment cast cylinders was 
revised from 8,000 to 6,000. Superior reported that the total 
production of the investment cast cylinders was only 34,487 cylinder 
assemblies.

Relevant Service Information

    Continental Motors Aircraft Engine Service Information Letter 
SIL98-9B, Revision B, dated April 8, 2013, provides relevant service 
information for this AD. That service information also includes 
information concerning time-between-overhaul.

FAA's Determination

    We are proposing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design.

Proposed AD Requirements

    This proposed AD would expand the list of applicable engines in AD 
2009-16-03 (74 FR 38896, August 5, 2009), to include the CMI 470 series 
reciprocating engines modified by STC to accept CMI 520 or 550 
cylinders, with certain replacement PMA SAP investment cast cylinder 
assemblies installed. This proposed AD would also clarify the 
identification of SAP cylinder assemblies.

Costs of Compliance

    We estimate that this proposed AD would affect 6,000 engines 
installed on airplanes of U.S. registry. We also estimate that it would 
take about 5 hours to replace a cylinder, and 15 hours per engine to 
inspect the

[[Page 56624]]

cylinders. The average labor rate is $85 per hour. Required parts would 
cost about $1,200 per cylinder. We anticipate that 4,000 cylinders 
would require replacement. Based on these figures, we estimate the 
total cost of the proposed AD to U.S. operators to be $14,150,000.

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),
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction, and
    (4) 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.

List of Subjects in 14 CFR Part 39

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

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 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 removing airworthiness directive (AD) 
2009-16-03, Amendment 39-15986 (74 FR 38896, August 5, 2009), and 
adding the following new AD:

Continental Motors, Inc. (formerly Teledyne Continental Motors, 
Continental): Docket No. FAA-2007-0051; Directorate Identifier 2007-
NE-37-AD.

(a) Comments Due Date

    The FAA must receive comments on this AD action by November 12, 
2013.

(b) Affected ADs

    This AD supersedes AD 2009-16-03, Amendment 39-15986 (74 FR 
38896, August 5, 2009).

(c) Applicability

    This AD applies to:
    (1) Continental Motors, Inc. (CMI) IO-520, TSIO-520, and IO-550 
series reciprocating engines with replacement parts manufacturer 
approval (PMA) Superior Air Parts, Inc. (SAP) investment cast 
cylinder assemblies, part numbers (P/Ns) SA52000-A1, SA52000-A20P, 
SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-
A20P, installed.
    (2) All other engine models approved for the use of CMI 520 and 
550 cylinder assemblies such as the CMI 470 series engines when 
modified by Supplemental Type Certificate (STC), with SAP investment 
cast cylinder assemblies, P/Ns SA52000-A1, SA52000-A20P, SA52000-
A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-A20P, 
installed.
    (3) This AD applies to all serial numbers for the P/Ns listed in 
paragraphs (c)(1) and (c)(2) of this AD.
    (4) If no SAP replacement cylinders were installed during engine 
maintenance since the CMI engines were new, then this AD does not 
apply.

(d) Unsafe Condition

    This AD was prompted by the need to add to the applicability all 
other engine models approved for the use of CMI 520 and 550 cylinder 
assemblies such as the CMI 470 series engines when modified by STC, 
with affected SAP investment cast cylinder assemblies installed. We 
are issuing this AD to prevent the separation of the cylinder head, 
damage to the engine, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(f) Identification of SAP Cylinder Assemblies

    Seeing the SAP cylinder assembly P/Ns referenced in paragraphs 
(c)(1) and (c)(2) of this AD may be difficult because the assembly 
P/Ns are stamped on the bottom cylinder flange. Therefore, you may 
review the engine maintenance records instead of the steps listed in 
paragraphs (f)(1) and (f)(2) of this AD, to see if the engine 
records identify the P/Ns of the cylinders installed. If the records 
do not identify the P/Ns of the cylinders installed, do the 
following:
    (1) Remove the valve cover from the cylinder assembly.
    (2) Look at the top of the cylinder head for the casting 
markings ``AMCAST'' or ``CP''. If a cylinder head has either of 
these markings, do the steps required by paragraphs (g) through (j) 
of this AD.

(g) Initial Inspection of SAP Cylinder Assemblies

    For engines and cylinders listed in paragraphs (c)(1) and (c)(2) 
of this AD, with cylinders over 750 flight hours (FH) time-in-
service (TIS) on the effective date of this AD, do the following 
initial inspection within 25 FH TIS.
    (1) Inspect each cylinder head around the exhaust valve side for 
visual cracks or any signs of black combustion leakage.
    (2) Replace any cracked or leaking cylinders before further 
flight.
    (3) Perform a standard cylinder compression test. Guidance on 
standard cylinder compression tests can be found in Teledyne 
Continental Aircraft Engine Service Bulletin SB03-3, Differential 
Pressure Test and Borescope Inspection Procedures for Cylinders, 
dated March 28, 2003.
    (i) If the cylinder pressure gauge reads below 60 pounds per-
square inch, determine if the unacceptable pressure is due to a 
cracked cylinder.
    (ii) To check the cylinder, apply a 2 percent soapy water 
solution to the side of the leaking cylinder.
    (iii) If you see air bubbles, indicating air leakage, on the 
side of the cylinder head, or near the head-to-cylinder interface, 
replace the cylinder assembly before further flight.

(h) Repetitive Inspections of SAP Cylinder Assemblies

    Thereafter, repeat the cylinder visual inspections and 
compression tests specified in paragraphs (g)(1) through (g)(3)(iii) 
of this AD, within every 50 FH time-since-last inspection until the 
cylinder reaches the TIS as listed in paragraph (i) of this AD.

(i) Replacing SAP Cylinder Assemblies

    For installed cylinders, replace the affected SAP cylinders at 
the earliest of the following:
    (1) When the cylinder reaches the operating hours TIS between 
overhaul limits, specified in Continental Motors Aircraft Engine 
Service Information Letter SIL98-9B, Revision B, dated April 8, 
2013; or
    (2) When the cylinder reaches 12 calendar years-since-
installation.

(j) Prohibition Against Installing Certain P/Ns of SAP Cylinder 
Assemblies

    After the effective date of this AD, do not install or reinstall 
after any removal, any SAP

[[Page 56625]]

investment cast cylinder assembly, P/Ns SA52000-A1, SA52000-A20P, 
SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-
A20P, in any engine.

(k) Alternative Methods of Compliance

    The Manager, Special Certification Office, may approve AMOCs to 
this AD. Use the procedures found in 14 CFR 39.19 to make your 
request.

(l) Special Flight Permits

    Under 14 CFR Part 39.23, we will not approve special flight 
permits for this AD for engines that have failed the visual 
inspection or the 50 hour periodic cylinder assembly compression 
test required by this AD.

(m) Related Information

    (1) For more information about this AD, contact Peter W. Hakala, 
Aerospace Engineer, Special Certification Office, FAA, Rotorcraft 
Directorate, 2601 Meacham Blvd., Fort Worth, TX 76193; phone: 817-
222-5145; fax: 817-222-5785; email: peter.w.hakala@faa.gov.
    (2) For Teledyne Continental Aircraft Engine Service Bulletin 
SB03-3, dated March 28, 2003, and Continental Motors Aircraft Engine 
Service Information Letter SIL98-9B, Revision B, dated April 8, 
2013, contact Continental Motors, Inc., 2039 Broad St., Mobile, AL 
36615; phone: 251-438-3411; Web site: http://www.continentalmotors.aero/Support_Materials/Publications/Service_Bulletins.
    (3) You may view this service information at the FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, 
MA. For information on the availability of this material at the FAA, 
call 781-238-7125.

    Issued in Burlington, Massachusetts, on September 3, 2013.
Colleen M. D'Alessandro,
Assistant Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2013-22273 Filed 9-12-13; 8:45 am]
BILLING CODE 4910-13-P