Document ID: FAA-2012-0896-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Various Restricted Category Helicopters
Posted Date: 2012-09-13T04:00Z

[Federal Register Volume 77, Number 178 (Thursday, September 13, 2012)]
[Rules and Regulations]
[Pages 56528-56533]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2012-22564]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2012-0896; Directorate Identifier 2010-SW-070-AD; 
Amendment 39-17173; AD 2012-17-10]
RIN 2120-AA64

Airworthiness Directives; Various Restricted Category Helicopters

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

ACTION: Final rule; request for comments.

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SUMMARY: We are adopting a new airworthiness directive (AD) for various 
restricted category Model HH-1K, TH-1F, TH-1L, UH-1A, UH-1B, UH-1E, UH-
1F, UH-1H, UH-1L, and UH-1P helicopters with certain main rotor (M/R) 
blade assemblies installed, to require inspecting the grip plates, 
doublers, and upper and lower surfaces of the M/R blades in the area 
between blade stations 24.5 and 40 for an edge void, corrosion, or a 
crack. This AD is prompted by several reports of fatigue cracks on M/R 
blades installed on Bell Helicopter Textron, Inc. (Bell) Model 212 
helicopters. These same part-numbered M/R blades may also be installed 
on certain FAA-approved modified restricted category helicopters. These 
actions are intended to detect an edge void, corrosion, or a crack on 
an M/R blade, which could lead to loss of the M/R blade and subsequent 
loss of control of the helicopter.

DATES: This AD becomes effective September 28, 2012.
    We must receive comments on this AD by November 13, 2012.

ADDRESSES: You may send comments by any of the following methods:
     Federal eRulemaking Docket: Go to http://www.regulations.gov. Follow the online instructions for sending your 
comments electronically.
     Fax: 202-493-2251.
     Mail: Send comments to the U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE., Washington, DC 20590-0001.
     Hand Delivery: Deliver to the ``Mail'' address between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    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

[[Page 56529]]

between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this AD, the economic evaluation, any 
comments received, and other information. The street address for the 
Docket Operations Office (telephone 800-647-5527) is in the ADDRESSES 
section. Comments will be available in the AD docket shortly after 
receipt.
    For service information identified in this AD, contact Bell 
Helicopter Textron, Inc., P.O. Box 482, Fort Worth, TX 76101; telephone 
(817) 280-3391; fax (817) 280-6466; or at http://www.bellcustomer.com/files/. You may review a copy of the referenced service information at 
the FAA, Office of the Regional Counsel, Southwest Region, 2601 Meacham 
Blvd., Room 663, Fort Worth, Texas 76137.

FOR FURTHER INFORMATION CONTACT: Michael Kohner, Aviation Safety 
Engineer, Rotorcraft Certification Office, Rotorcraft Directorate, FAA, 
2601 Meacham Blvd., Fort Worth, TX 76137; telephone (817) 222-5170; 
email 7-avs-asw-170@faa.gov.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety, and we did not provide you with notice and an opportunity to 
provide your comments prior to it becoming effective. However, we 
invite you to participate in this rulemaking by submitting written 
comments, data, or views. We also invite comments relating to the 
economic, environmental, energy, or federalism impacts that resulted 
from adopting this AD. The most helpful comments reference a specific 
portion of the AD, explain the reason for any recommended change, and 
include supporting data. To ensure the docket does not contain 
duplicate comments, commenters should send only one copy of written 
comments, or if comments are filed electronically, commenters should 
submit them only one time. We will file in the docket all comments that 
we receive, as well as a report summarizing each substantive public 
contact with FAA personnel concerning this rulemaking during the 
comment period. We will consider all the comments we receive and may 
conduct additional rulemaking based on those comments.

Discussion

    This AD is prompted by several reports of fatigue cracks on M/R 
blades installed on Bell Model 212 helicopters. The cracks were found 
in the lower skin, doublers, and box beam at the M/R blade attachment 
bolt hole, and through the lower grip plate at blade station (BS) 36. 
Because the fatigue cracks were discovered on M/R blades installed on 
the Bell Model 212 helicopters, we issued AD No. 2010-03-03, Amendment 
39-16186 (75 FR 5681, February 4, 2010) (AD 2010-03-03) for certain 
Bell Model 205B and 212 helicopters. That AD required visually 
inspecting the M/R blades for an edge void, corrosion, or a crack. 
After issuing that AD, we received another report of a fatigue crack on 
a M/R blade installed on a Model 212 helicopter. Further analysis by 
the manufacturer revealed that the inspections required by AD 2010-03-
03 needed to be expanded and performed at an increased frequency, and 
on additional part-numbered M/R blades which can also be installed on 
other Bell model helicopters. We then issued AD No. 2011-23-02 (76 FR 
68301, November 4, 2011) (AD 2011-23-02), which superseded AD 2010-03-
03. AD 2011-23-02 retained the requirements of the superseded AD, 
increased the frequency and scope of the inspections required by that 
AD, and expanded the applicability to include the Model 205A-1 and 210 
helicopters, additional M/R blade part numbers, and all helicopter 
serial numbers for the affected models.
    Since the issuance of AD 2011-23-02, we have determined that the 
same part-numbered M/R blades can also be installed on certain FAA-
approved modified restricted category helicopters. Therefore, we are 
mandating the inspection requirements for the applicable restricted 
category helicopters. The actions specified in this AD are intended to 
detect an edge void, corrosion, or a crack on an M/R blade, which could 
lead to loss of the M/R blade and subsequent loss of control of the 
helicopter.

FAA's Determination

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

Related Service Information

    Bell has issued Alert Service Bulletin (ASB) No. 205B-08-51 dated 
January 11, 2011 (ASB 205B-08-51) for Model 205B helicopters, ASB No. 
210-08-03 dated January 10, 2011 (ASB 210-08-03) for the Model 210 
helicopters, and ASB No. 212-08-130 dated January 11, 2011 (ASB 212-08-
130) for Model 212 helicopters, all revision B. The ASBs describe 
procedures to detect an edge void, corrosion, or a crack in the upper 
and lower grip plates, doublers, and blade skins of the M/R blade 
between blade stations 24.5 and 85.

AD Requirements

    This AD requires, within 25 hours time-in-service (TIS), and 
thereafter at intervals not to exceed 25 hours TIS, the following 
actions:
     Washing the upper and lower M/R blade surfaces using a 
solution of cleaning compound and water;
     Visually inspecting the upper and lower grip plates, 
doublers, and remaining surfaces of the M/R blade in an area from blade 
stations 24.5 to 40, including the entire width of the M/R blade chord 
width for an edge void, any corrosion, or a crack;
     Wiping each of the bond lines at the edges of both grip 
plates and each of the layered doublers with an alcohol-soaked cloth 
for their entire length and chord width and, using a 3x power or higher 
magnifying glass and a bright light, visually inspecting each of the 
bond lines on the upper and lower surfaces of the M/R blade for an edge 
void, any corrosion, or any edge delamination, as indicated by a crack 
in the paint finish.
     If there is an edge delamination or a crack in the paint 
finish, removing paint from areas in which an edge delamination along 
any bond line of a grip plate or doubler or a crack in the M/R blade 
paint finish is discovered to determine if an edge void or a crack 
exists in the M/R blade and, if there is not an edge void or a crack, 
refinishing the sanded area;
     Applying a light coat of preservative oil to all surfaces 
of the M/R blade;
     Replacing any M/R blade that has an edge void or any 
corrosion with an airworthy M/R blade or repairing the M/R blade if the 
damage is within the maximum repair damage limits;
     Replacing any M/R blade that has a crack in any grip plate 
or doubler with an airworthy M/R blade; and
     Replacing any M/R blade that has a crack in the M/R blade 
skin with an airworthy M/R blade, or repairing the M/R blade if the 
damage is within the maximum repair damage limits.

Differences Between This AD and the Service Information

    This AD applies to various restricted category Model HH-1K, TH-1F, 
TH-1L, UH-1A, UH-1B, UH-1E, UH-1F, UH-1H, UH-1L, and UH-1P helicopters; 
ASB 205B-08-51, ASB 210-08-03, and ASB 212-08-130 apply to Model 205B, 
210, and 212 helicopters, respectively.
    This AD also differs from the ASBs as follows:
     We do not include the requirement to inspect for a dark 
line along any of

[[Page 56530]]

the bond lines after wiping with an alcohol-soaked cloth to detect an 
edge void or edge delamination as stated in the ASBs. The alcohol is 
only being used as a cleaning agent for the purposes of this AD.
     This AD requires inspecting for an edge void, a crack, or 
any corrosion in an area from blade stations 24.5 to 40, including the 
entire width of the M/R blade chord, while the ASBs require inspecting 
from blade stations 24.5 to 85. This AD includes the inspections of the 
bondlines for their entire length and chord width for an edge 
delamination or for a crack in the paint finish, while the ASB 
inspections do not.
     The ASBs use the phrase ``bond lines between doublers, 
grip plates, and skin'' to describe the bond lines, and we use ``bond 
lines at the edges of both grip plates and each of the layer 
doublers.''
     The ASBs use the phrase ``cracks in the bond lines between 
doublers or grip plates'' to describe a separation of the doubler or 
grip plate along an edge, and we use the term ``edge delamination.''

Costs of Compliance

    We estimate that this AD will affect 25 helicopters of U.S. 
Registry.
    We estimate that operators may incur the following costs in order 
to comply with this AD. Washing and visually inspecting each M/R blade 
requires one work hour at an average labor rate of $85 per hour, for a 
cost per helicopter of $85 and a total cost to the U.S. operator fleet 
of $2,125 per inspection cycle. If an edge void, corrosion, or a crack 
is found, replacing an M/R blade with an airworthy M/R blade requires 
approximately 24 work hours at an average labor rate of $85 per hour, 
and required parts cost $121,875, for a total cost for each M/R blade 
replacement of $123,915.

FAA's Justification and Determination of the Effective Date

    The short compliance time is required because the previously 
described critical unsafe condition can adversely affect the structural 
integrity and controllability of the helicopter. In addition, the 
various restricted category helicopters are high usage aircraft, and 
they could reach 100 hours TIS within 60 days. Therefore, the actions 
described previously are required within 25 hours TIS, a short 
compliance time, and are to be repeated thereafter at intervals not to 
exceed 25 hours TIS, and this AD must be issued immediately.
    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we determined that notice and opportunity for 
public comment before issuing this AD are impracticable and that good 
cause exists for making this amendment effective in less than 30 days.

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 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, I certify that this AD:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under 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.
    We prepared an economic evaluation of the estimated costs to comply 
with this AD and placed it in the AD docket.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 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 adding the following new airworthiness 
directive (AD):

2012-17-10 Various Restricted Category Helicopters: Amendment 39-
17173; Docket No. FAA-2012-0896; Directorate Identifier 2010-SW-070-
AD.

(a) Applicability

    This AD applies to restricted category Model HH-1K, TH-1F, TH-
1L, UH-1A, UH-1B, UH-1E, UH-1F, UH-1H, UH-1L, and UH-1P helicopters 
with a main rotor (M/R) blade, part number (P/N) 204-012-001-023 or 
-033; 210-015-001-101; 212-015-501-005, -111, -113, -115, -117, -
119, or -121, installed, certificated in any category.

(b) Unsafe Condition

    This AD defines the unsafe condition as an edge void, corrosion, 
or a crack on an M/R blade. This condition could lead to loss of the 
M/R blade and subsequent loss of control of the helicopter.

(c) Effective Date

    This airworthiness directive (AD) becomes effective September 
28, 2012.

(d) Compliance

    You are responsible for performing each action required by this 
AD within the specified compliance time unless it has already been 
accomplished prior to that time.

(e) Required Actions

    (1) Within 25 hours time-in-service (TIS), and thereafter at 
intervals not to exceed 25 hours TIS:
    (i) Wash the upper and lower surfaces of each affected M/R blade 
with a solution of cleaning compound (C-318) and water. Rinse 
thoroughly and wipe dry.
    (ii) Using a 3x power or higher magnifying glass and a bright 
light, on each affected M/R blade, in an area from blade stations 
24.5 to 40, including the entire width of the M/R blade chord, as 
depicted in Figure 1 to Paragraph (e) of this AD:

[[Page 56531]]

[GRAPHIC] [TIFF OMITTED] TR13SE12.001

    (A) Visually inspect the upper and lower grip plates and 
doublers of the M/R blade for an edge void, any corrosion, or a 
crack.
    (B) Visually inspect the remaining upper and lower surfaces of 
the M/R blade for an edge void, any corrosion, or a crack.

    Note 1 to paragraphs (e)(1)(ii) and (e)(1)(iv):  The inspections 
required by paragraphs (e)(1)(ii) and (e)(1)(iv) of this AD do not 
require removal of the M/R blades from the M/R hub and can be 
accomplished while the M/R blades are installed on the helicopter.

    Note 2 to paragraph (e)(1)(ii):  Crack indications on an actual 
M/R blade are shown in Figure 2 to Paragraph (e) of this AD.

[[Page 56532]]

[GRAPHIC] [TIFF OMITTED] TR13SE12.002

    (iii) Wipe each of the bond lines at the edges of both grip 
plates and each of the layered doublers (bond lines) on the upper 
and lower surfaces of each affected M/R blade with an alcohol-soaked 
cloth (C-385) for their entire length and chord width. Wipe dry with 
a clean cloth.
    (iv) Using a 3x power or higher magnifying glass and a bright 
light, visually inspect each of the bond lines on the upper and 
lower surfaces of the M/R blade for their entire length and chord 
width for an edge void, any corrosion, or any edge delamination, as 
indicated by a crack in the paint finish. An edge delamination is 
defined as a separation of the detail parts along an edge.

    Note 3 to paragraph (e)(1)(iv):  A crack in the paint finish 
which follows the outline of a grip plate or doubler may indicate a 
possible edge void.

    (v) If there is any edge delamination along any bond line of a 
grip plate or doubler, or a crack in the paint finish, before 
further flight, remove the paint in the affected area by lightly 
sanding with 180-220 grit paper in a span-wise direction to 
determine if there is an edge void, or if the grip plate, doubler, 
or skin is cracked. If any parent material is removed during the 
sanding operation, replace the M/R blade with an airworthy M/R blade 
or repair the M/R blade if the amount of parent material removed is 
within the maximum repair damage limits. If there is no edge void or 
crack, refinish the sanded area.

    Note 4 to paragraphs (e)(1)(v) and (e)(2):  The maximum repair 
damage limits are contained in the applicable Component and Repair 
Overhaul Manual.

    (vi) If there is no edge void, corrosion, or crack, apply a 
light coat of preservative oil (C-125) to all surfaces of each 
affected M/R blade.
    (2) If an edge void, any corrosion, or a crack is discovered 
during any inspections in paragraph (e)(1) of this AD, before 
further flight, accomplish the following:
    (i) If there is an edge void, determine the depth and length 
using a .0015 inch feeler gauge.
    (ii) If there is an edge void in a grip plate or doubler near 
the outboard tip, tap inspect the affected area to determine the 
size and shape of the void.
    (iii) Repair the M/R blade if the edge void is within the 
maximum repair damage limits or replace the M/R blade with an 
airworthy M/R blade.

[[Page 56533]]

    (iv) If there is any corrosion, replace the M/R blade with an 
airworthy M/R blade or repair the M/R blade if the damage is within 
the maximum repair damage limits.
    (v) If there is a crack in any grip plate or doubler, replace 
the M/R blade with an airworthy M/R blade.
    (vi) If there is a crack in the M/R blade skin, replace the M/R 
blade with an airworthy M/R blade, or repair the M/R blade if the 
damage is within the maximum repair damage limits.

(f) Special Flight Permits

    Special flight permits will be permitted for flights to an 
authorized inspection and repair facility provided the one-time 
ferry flight does not exceed 5 hours TIS and is for the 
accomplishment of an inspection only.

(g) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Rotorcraft Certification Office, FAA, may 
approve AMOCs for this AD. Send your proposal to: Michael Kohner, 
Aviation Safety Engineer, Rotorcraft Certification Office, 
Rotorcraft Directorate, FAA, 2601 Meacham Blvd., Fort Worth, TX 
76137; telephone (817) 222-5170; email 7-avs-asw-170@faa.gov.
    (2) For operations conducted under a 14 CFR part 119 operating 
certificate or under 14 CFR part 91, subpart K, we suggest that you 
notify your principal inspector, or lacking a principal inspector, 
the manager of the local flight standards district office or 
certificate holding district office before operating any aircraft 
complying with this AD through an AMOC.

(h) Additional Information

    Bell Helicopter Alert Service Bulletin (ASB) No. 205B-08-51 
Revision B, dated January 11, 2011, for Model 205B helicopters, ASB 
No. 210-08-03 Revision B, dated January 10, 2011 for the Model 210 
helicopters, and ASB No. 212-08-130 Revision B, dated January 11, 
2011, for Model 212 helicopters, which are not incorporated by 
reference, contain additional information about the subject of this 
AD. For service information identified in this AD, contact Bell 
Helicopter Textron, Inc., P.O. Box 482, Fort Worth, TX 76101; 
telephone (817) 280-3391; fax (817) 280-6466; or at http://www.bellcustomer.com/files/. You may review a copy of this service 
information at the FAA, Office of the Regional Counsel, Southwest 
Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas 76137.

(i) Subject

    Joint Aircraft Service Component (JASC) Code: 6210: Main Rotor 
Blades.

    Issued in Fort Worth, Texas, on August 21, 2012.
Lance T. Gant,
Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 2012-22564 Filed 9-12-12; 8:45 am]
BILLING CODE 4910-13-P