Document ID: FAA-2009-0518-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Sikorsky Aircraft Corporation Model S-92A Helicopters
Posted Date: 2009-06-16T04:00Z

[Federal Register: June 16, 2009 (Volume 74, Number 114)]
[Rules and Regulations]               
[Page 28439-28441]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr16jn09-1]                         

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Rules and Regulations
                                                Federal Register
________________________________________________________________________

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to and codified in the Code of Federal Regulations, which is published 
under 50 titles pursuant to 44 U.S.C. 1510.

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[[Page 28439]]

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0518; Directorate Identifier 2009-SW-22-AD; 
Amendment 39-15940; AD 2009-13-01]
RIN 2120-AA64

 
Airworthiness Directives; Sikorsky Aircraft Corporation Model S-
92A Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

-----------------------------------------------------------------------

SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD) for Sikorsky Aircraft Corporation (Sikorsky) Model S-92A 
helicopters. That AD currently requires removing all main gearbox (MGB) 
filter bowl assembly mounting titanium studs (titanium studs) and 
replacing them with steel studs. This amendment requires the same 
actions as the existing AD as well as changes to the Rotorcraft Flight 
Manual (RFM). This amendment is prompted by an accident, by recent RFM 
changes made by the manufacturer that were not available when we issued 
the existing AD, and by our determination that certain MGB Normal and 
Emergency procedures in the RFM are unclear, may cause confusion, and 
may mislead the crew regarding MGB malfunctions, in particular the 
urgency to land immediately after warning indications of loss of MGB 
oil pressure and oil pressure below 5 pounds per square inch (psi).
    Replacing the titanium studs is intended to prevent their failure, 
which could result in rapid loss of oil, failure of the MGB, and 
subsequent loss of control of the helicopter. Changing the RFM 
procedures is intended to clarify and emphasize certain Normal and 
Emergency procedures to give the crew the best available information in 
the event of certain MGB malfunctions.

DATES: Effective July 1, 2009.
    The incorporation by reference of Sikorsky Alert Service Bulletin 
No. 92-63-014, Revision A, dated March 20, 2009, was approved 
previously for incorporation by reference by the Director of the 
Federal Register on April 27, 2009 (74 FR 18977, April 27, 2009).
    Comments for inclusion in the Rules Docket must be received on or 
before August 17, 2009.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
     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: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue, SE., Washington, DC 20590, 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 
Sikorsky Aircraft Corporation, Attn: Manager, Commercial Technical 
Support, mailstop s581a, 6900 Main Street, Stratford, CT, telephone 
(203) 383-4866, e-mail address tsslibrary@sikorsky.com, or at http://
www.sikorsky.com.
    Examining the Docket: You may examine the docket that contains the 
AD, any comments, and other information 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 Docket Operations office (telephone (800) 647-5527) is 
located in Room W12-140 on the ground floor of the West Building at the 
street address stated in the ADDRESSES section. Comments will be 
available in the AD docket shortly after receipt.

FOR FURTHER INFORMATION CONTACT: John M. Coffey, Flight Test Engineer, 
FAA, 12 New England Executive Park, Burlington, MA 01803, telephone 
(781) 238-7173, fax (781) 238-7170.

SUPPLEMENTARY INFORMATION: On March 23, 2009, we issued Emergency AD 
2009-07-53 for Sikorsky Model S-92A helicopters, which requires, before 
further flight, removing all titanium studs that attach the MGB filter 
bowl assembly to the MGB and replacing them with steel studs. That 
action was prompted by the failure of 2 studs that were found broken 
during a fatal accident investigation in Canada. Before the accident, 
the manufacturer was investigating a July 2008 incident that also 
involved broken studs. In both cases, the broken studs resulted in 
rapid loss of MGB oil. The failures have been tied to fretting and 
galling of the original titanium studs. That emergency AD was published 
as Amendment 39-15886 on April 27, 2009 (74 FR 18977). This AD 
continues to require removing all titanium studs and replacing them 
with steel studs.
    Since the fatal accident and since issuing AD 2009-07-53, Sikorsky 
has issued revisions to the Normal and Emergency procedures of the RFM. 
We have determined that these revisions are necessary because the 
existing procedures are unclear, may cause confusion, and may mislead 
the crew regarding MGB malfunctions, in particular the urgency to land 
immediately after warning indications of loss of MGB oil pressure and 
oil pressure below 5 psi. This action does not mandate the procedures 
the pilot must perform in an emergency, but requires making changes to 
the RFM to clarify and emphasize the Normal and Emergency procedures 
addressing specified MGB malfunctions, thus giving the pilot the 
necessary information to make an informed decision. We are superseding 
the existing AD to include the most recent RFM revisions because the 
revisions were not available when we originally issued AD 2009-07-53.
    We have reviewed Sikorsky Alert Service Bulletin No. 92-63-014A, 
Revision A, dated March 20, 2009 (ASB), which describes procedures for 
removing titanium studs and replacing them with steel suds. We have 
also reviewed the RFM revisions and, after full coordination with 
Sikorsky, approved them on May 13, 2009. Sikorsky has since assured us 
that they have provided the revised RFM procedures to all affected 
operators. The RFM revisions are as follows:

[[Page 28440]]

     SA S92A-RFM-000 Revision No. 4,
     SA S92A-RFM-002 Revision No. 10,
     SA S92A-RFM-003 Revision No. 10,
     SA S92A-RFM-004 Revision No. 8,
     SA S92A-RFM-005 Revision No. 7,
     SA S92A-RFM-006 Revision No. 8, and
     S92A-RFM Supplement No. 3, Revision No. 2.
    In addition to the RFM revisions, we have also reviewed associated 
Errata Sheets, dated June 4, 2009, that provide corrections to those 
RFM revisions; however, we are not mandating that they be incorporated.
    Since an unsafe condition has been identified that is likely to 
exist or develop on other Sikorsky Model S-92A helicopters of the same 
type design, this AD supersedes AD 2009-07-53 to require, before 
further flight, removing all titanium studs and replacing them with 
steel studs. These actions must be accomplished by following the 
specified portions of the ASB described previously. Because the 
critical unsafe condition can adversely affect the structural integrity 
and controllability of the helicopter, AD 2009-07-53 remains in full 
effect until the effective date of this AD.
    Making the Normal and Emergency RFM revisions that were not 
available when we issued AD 2009-07-53 is required within 10 hours 
time-in-service. The short compliance time is required because certain 
procedures in the existing RFM may be misleading, presenting an 
unacceptable level of risk, and because the required RFM revisions are 
already approved by the FAA and available to operators, imposing a 
minimal burden. Therefore, it is found that notice and opportunity for 
prior public comment hereon are unnecessary and contrary to the public 
interest, and that good cause also exists for making this amendment 
effective in less than 30 days.
    We estimate that this AD will affect 35 helicopters of U.S. 
registry. Replacing the studs will take approximately 6 work hours per 
helicopter to accomplish at an average labor rate of $80 per work hour. 
In accordance with the ASB, required parts and tooling are available at 
no cost. Making the changes to the RFM will take a minimal amount of 
time and cost. Based on these figures, we estimate the total cost 
impact of the AD on U.S. operators to be $16,800, assuming there are no 
parts and tooling costs.

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-2009-0518; Directorate 
Identifier 2009-SW-22-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://
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 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).

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 AD docket 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.

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 removing Amendment 39-15886 (74 FR 
18977, April 27, 2009), and by adding a new airworthiness directive 
(AD), Amendment 39-15940, to read as follows:

2009-13-01 Sikorsky Aircraft Corporation: Amendment 39-15940. Docket 
No. FAA-2009-0518; Directorate Identifier 2009-SW-22-AD. Supersedes 
AD 2009-07-53, Amendment 39-15886, Docket No. FAA-2009-0351, 
Directorate Identifier 2009-SW-08-AD.

    Applicability: Model S-92A helicopters, certificated in any 
category.
    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent failure of a main gearbox (MGB) filter bowl assembly 
mounting titanium stud (titanium stud), which could result in rapid 
loss of oil, failure of the MGB, and subsequent loss of control of 
the helicopter; and to clarify and emphasize certain Normal and 
Emergency procedures to give the crew the best available information 
in the event of certain MGB malfunctions, accomplish the following:
    (a) Before further flight, for all Model S-92A helicopters with 
a MGB housing assembly, part number (P/N) 92351-15110-042, -043, or 
-044, that is not marked with ``TS-062-01'' near the P/N:
    (1) Remove the titanium studs by following the Accomplishment 
Instructions in Sikorsky Alert Service Bulletin No. 92-63-014, Rev.

[[Page 28441]]

A, dated March 20, 2009 (ASB), paragraph 3.A.

    Note 1: Figure 1 of the ASB contains guidance for removal and 
installation of the studs

    .(2) Visually inspect the tapped holes and the MGB housing 
lockring counterbore for damage. If you find damage in the tapped 
holes or in the MGB housing lockring counterbore, contact the Boston 
Aircraft Certification Office for an approved repair.
    (3) Install steel studs and mark the MGB housing as ``TS-062-
01'' near the P/N by following the Accomplishment Instructions in 
the ASB, paragraph 3.C.
    (b) Within 10 hours time-in-service, for all helicopters 
regardless of MGB housing assembly P/N:
    (1) Revise the Normal and Emergency procedures sections of the 
Rotorcraft Flight Manual (RFM) by making the following changes, 
approved May 13, 2009:

----------------------------------------------------------------------------------------------------------------
                RFM                          Remove                  Remove                     Insert
----------------------------------------------------------------------------------------------------------------
SA S92A-RFM-000 Part I.............  Temporary Revision (T-  Page 2-12, and Sub-     Page 2-12, and Sub-Section
                                      Rev) No. 1, Revised     Section 7 ``Gear Box    7 ``Gear Box
                                      Main Gearbox            Malfunctions'' from     Malfunctions'' from
                                      Emergency Procedure.    Section III.            Section III of SA S92A-RFM-
                                                                                      000, Revision No. 4.
SA S92A-RFM-002 Part I.............  T-Rev No. 5, Revised    Page 2-13, and Sub-     Page 2-13, and Sub-Section
                                      Main Gearbox            Section 7 ``Gear Box    7 ``Gear Box
                                      Emergency Procedure.    Malfunctions'' from     Malfunctions'' from
                                                              Section III.            Section III of SA S92A-RFM-
                                                                                      002, Revision No. 10.
SA S92A-RFM-003 Part I.............  T-Rev No. 4, Revised    Page 2-13, and Sub-     Page 2-13, and Sub-Section
                                      Main Gearbox            Section 7 ``Gear Box    7 ``Gear Box
                                      Emergency Procedure.    Malfunctions'' from     Malfunctions'' from
                                                              Section III.            Section III of SA S92A-RFM-
                                                                                      003, Revision No. 10.
SA S92A-RFM-004 Part I.............  T-Rev No. 4, Revised    Page 2-12, and Sub-     Page 2-12, and Sub-Section
                                      Main Gearbox            Section 7 ``Gear Box    7 ``Gear Box
                                      Emergency Procedure.    Malfunctions'' from     Malfunctions'' from
                                                              Section III.            Section III of SA S92A-RFM-
                                                                                      004, Revision No. 8.
SA S92A-RFM-005 Part I.............  T-Rev No. 3, Revised    Page 2-13, and Sub-     Page 2-13, and Sub-Section
                                      Main Gearbox            Section 7 ``Gear Box    7 ``Gear Box
                                      Emergency Procedure.    Malfunctions'' from     Malfunctions'' from
                                                              Section III.            Section III of SA S92A-RFM-
                                                                                      005, Revision No. 7.
SA S92A-RFM-006 Part I.............  T-Rev No. 2, Revised    Page 2-13, and Sub-     Page 2-13, and Sub-Section
                                      Main Gearbox            Section 7 ``Gear Box    7 ``Gear Box
                                      Emergency Procedure.    Malfunctions'' from     Malfunctions'' from
                                                              Section III.            Section III of SA S92A-RFM-
                                                                                      006, Revision No. 8.
S92A-RFMS No. 3....................  N/A...................  Sub-Section 7 ``Gear    Sub-Section 7 ``Gear Box
                                                              Box Malfunctions''      Malfunctions'' from
                                                              from Section III.       Section III of
                                                                                      S92A[dash]RFM Supplement
                                                                                      No. 3, Revision No. 2.
----------------------------------------------------------------------------------------------------------------
All paragraphs of subsection 7 ``Gear Box Malfunctions'' starting with paragraph 7.0 are affected.
----------------------------------------------------------------------------------------------------------------

    Note 2: Inserting the following revisions, approved on May 13, 
2009, and their associated Errata Sheets, dated June 4, 2009, into 
the RFM, as applicable, satisfies the requirements of this AD:
    (i) SA S92A-RFM-000 Revision No. 4,
    (ii) SA S92A-RFM-002 Revision No. 10,
    (iii) SA S92A-RFM-003 Revision No. 10,
    (iv) SA S92A-RFM-004 Revision No. 8,
    (v) SA S92A-RFM-005 Revision No. 7,
    (vi) SA S92A-RFM-006 Revision No. 8, and
    (vii) S92A-RFM Supplement No. 3, Revision No. 2.

    (c) 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 Manager, Boston Aircraft Certification Office, FAA, 
Attn: John M. Coffey, FAA, 12 New England Executive Park, 
Burlington, MA 01803, telephone (781) 238-7173, fax (781) 238-7170, 
for information about previously approved alternative methods of 
compliance.
    (d) Special flight permits will not be issued.
    (e) Remove and replace the titanium studs by following the 
specified portions of Sikorsky Alert Service Bulletin No. 92-63-014, 
Revision A, dated March 20, 2009. The Director of the Federal 
Register previously approved the incorporation by reference of this 
information on April 27, 2009 under 5 U.S.C. 552(a) and 1 CFR part 
51 (74 FR 18977, April 27, 2009. Copies may be obtained from 
Sikorsky Aircraft Corporation, Attn: Manager, Commercial Technical 
Support, mailstop s581a, 6900 Main Street, Stratford, CT, telephone 
(203) 383-4866, e-mail address tsslibrary@sikorsky.com or at http://
www.sikorsky.com. Copies may be inspected at the FAA, Office of the 
Regional Counsel, Southwest Region, 2601 Meacham Blvd., Room 663, 
Fort Worth, Texas, or at the National Archives and Records 
Administration (NARA). For information on the availability of this 
material at NARA, call 202-741-6030, or go to: http://
www.archives.gov/federal_register/code_of_federal_regulations/
ibr_locations.html.
    (f) This amendment becomes effective on July 1, 2009.

    Issued in Fort Worth, Texas, on June 9, 2009.
Mark R. Schilling,
Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. E9-14081 Filed 6-15-09; 8:45 am]

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