Document ID: FAA-2007-0051-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Teledyne Continental Motors (TCM) IO- 520, TSIO-520, and IO-550 Series Engines with Superior Air Parts, Inc. (SAP) Cylinder Assemblies Installed
Posted Date: 2008-04-11T04:00Z

[Federal Register: April 11, 2008 (Volume 73, Number 71)]
[Proposed Rules]               
[Page 19772-19775]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr11ap08-12]                         

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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; Teledyne Continental Motors (TCM) IO-
520, TSIO-520, and IO-550 Series Engines with Superior Air Parts, Inc. 
(SAP) Cylinder Assemblies Installed

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

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for certain TCM IO-520, TSIO-520, and IO-550 reciprocating engines with 
certain SAP cylinder assemblies installed. This proposed AD would 
require initial and repetitive inspections and compression tests to 
detect cracks in those cylinders with more than 750 flight hours time-
in-service (TIS). This proposed AD results 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 part numbers. We are 
proposing this AD to prevent separation of the cylinder head, which 
could result in immediate loss of engine power, possible structural 
damage to the engine, and possible fire in the engine compartment.

DATES: We must receive any comments on this proposed AD by June 10, 
2008.

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.

FOR FURTHER INFORMATION CONTACT: Tausif Butt, Aerospace Engineer, 
Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd, Fort Worth, TX 76137-4298; e-mail: tausif.butt@faa.gov; telephone 
(817) 222-5195; fax (817) 222-5785.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2007-0051; Directorate 
Identifier 2007-NE-37-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.

[[Page 19773]]

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

    Superior Air Parts and operators in the field have reported 24 SAP 
cylinder assemblies with cracks or separation in the area of the 
exhaust valves. Some instances resulted in forced landings of the 
airplanes. The reported failures were cylinder assemblies in the 
naturally-aspirated and turbocharged engines. Most of the failures were 
on airplanes that have a high ratio of takeoffs and landings per flight 
hour. Most of the failures also occurred on airplanes that are operated 
predominantly at low altitude. SAP first informed us on July 12, 2006, 
that at least 14 SAP investment cast cylinder assemblies, P/Ns SA52000-
A1, SA52000-A20P, SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, 
SA55000-A20P, had cracked in the area of the exhaust valve of the 
cylinder head since the year 2000. We received reports of 10 additional 
failures since that time, and the total number of reported failures is 
currently 24. We determined that the minimum wall thickness of the SAP 
cylinder assemblies, P/Ns SA52000-A1, SA52000-A20P, SA52000-A21P, 
SA52000-A22P, SA52000-A23P, SA55000-A1, SA55000-A20P, is significantly 
thinner in the failure location than the original equipment 
manufacturer (OEM) cylinders. We certified the SAP cylinders as 
equivalent replacement Parts Manufacturer Approval (PMA) parts for TCM 
520 and 550 series engines, however, this design discrepancy results in 
stresses in the cylinder wall that are much higher in the SAP cylinder 
assemblies than in the OEM cylinder assemblies when subjected to 
identical loading. These higher stresses result in a lower fatigue life 
for the SAP cylinder assemblies relative to that of the OEM parts. The 
time-to-cracking or separation for this failure mode ranges between 823 
hours time-since-new (TSN) and 1,985 TSN. The thin-wall thickness 
condition in the area of the exhaust valve seat of the cylinder head 
has been present since the initial SAP design, and it is present in all 
SAP cylinders of that design that have been manufactured to date. This 
condition, if not corrected, could result in immediate loss of engine 
power, possible structural damage to the engine, and possible fire in 
the engine compartment.

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. We are proposing this AD, which would require 
inspecting or replacing, or both, certain SAP cylinder assemblies 
within 25 flight hours TIS after the effective date of the proposed AD 
for cylinders that are at their respective time-before-overhaul (TBO) 
TIS flight hours or have exceeded their respective TBO TIS flight 
hours.

Costs of Compliance

    We estimate that this proposed AD could affect 8,000 engines 
installed on airplanes of U.S. registry. We also estimate that it would 
take about 5 work-hours per cylinder to perform the proposed actions, 
and that the average labor rate is $80 per work-hour. Required parts 
would cost about $1,150 per cylinder. Based on these figures, we 
estimate the total cost of the proposed AD to U.S. operators to be 
$12,400,000.

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 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. You may get a copy of this summary at the 
address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, 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 adding the following new 
airworthiness directive:

Superior Air Parts, Inc. (SAP): Docket No. FAA-2007-0051; 
Directorate Identifier 2007-NE-37-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by June 10, 
2008.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Teledyne Continental Motors (TCM) IO-520, 
TSIO-

[[Page 19774]]

520, and IO-550 series engines with SAP cylinder assemblies, part 
numbers (P/Ns) SA52000-A1, SA52000-A20P, SA52000-A21P, SA52000-A22P, 
SA52000-A23P, SA55000-A1, or SA55000-A20P, installed. These engines 
are installed on, but not limited to, the airplanes listed in Table 
1 of this AD.

      Table 1.--Teledyne Continental Motors-Related Aircraft Models
------------------------------------------------------------------------
                                    Aircraft           Aircraft model
        Engine model              manufacturer           designation
------------------------------------------------------------------------
IO-520-A....................  Cessna..............  210 D, E, F, G, & H
IO-520-A....................  Cessna..............  206
IO-520-A....................  Cessna..............  P206
IO-520-A....................  Rockwell............  200 D
IO-520-B....................  Beechcraft..........  36 Bonanza
IO-520-B....................  Beechcraft..........  A36
IO-520-B....................  Navion..............  Range Master
IO-520-BA...................  Beechcraft..........  A36
IO-520-BA...................  Beechcraft..........  S & V35, V35A, V35B
IO-520-BA...................  Beechcraft..........  C33 A
IO-520-BA...................  Beechcraft..........  E33 A & C
IO-520-BA...................  Beechcraft..........  F33 A & C
IO-520-BA...................  Navion..............  Range Master
IO-520-BB...................  Beechcraft..........  A36
IO-520-BB...................  Beechcraft..........  V35B
IO-520-BB...................  Beechcraft..........  F33 A
IO-520-C & CB...............  Beechcraft..........  C55--E55 Baron
IO-520-D....................  Bellanca............  17-30 Viking
IO-520-D....................  Cessna..............  A188-300 AG Truck
IO-520-D....................  Cessna..............  185
IO-520-E....................  (Cessna 310)........  Exec 600
IO-520-E....................  (Beech Baron).......  Pres 600
IO-520-F....................  Cessna..............  207
IO-520-F....................  Cessna..............  U206
IO-520-K....................  Bellanca............  17-30A
IO-520-L....................  Cessna..............  210 K, L, M, N & R
IO-520-L....................  Cessna..............  210N II
IO-520-L....................  Cessna..............  210R
IO-520-M....................  Cessna..............  310R
IO-520-MB...................  Cessna..............  310R
IO-550-A....................  Cessna..............  310 Conversion
IO-550-B....................  Beechcraft..........  A36
IO-550-B....................  (Beech Bonanza).....  Foxstar
IO-550-C....................  Beechcraft..........  58 Baron
IO-550-D....................  Cessna..............  185/188 Conversion
IO-550-E....................  Cessna..............  310 Conversion
IO550-F.....................  Cessna..............  206/207 Conversion
IO-550-L....................  Cessna..............  210 Conversion
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results 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 part numbers. We are issuing 
this AD to prevent separation of the cylinder head, which could 
result in immediate loss of engine power, possible structural damage 
to the engine, and possible fire in the engine compartment.

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.

Inspecting SAP Cylinder Assemblies

    (f) For TCM IO-520, TSIO-520, and IO-550 series engines with SAP 
cylinder assemblies, P/Ns SA52000-A1, SA52000-A20P, SA52000-A21P, 
SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-A20P, installed, 
with over 750 flight hours time-in-service (TIS), do the following 
within 25 flight hours TIS after the effective date of this AD:
    (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.
    (3) Perform a standard cylinder compression test using paragraph 
8-14., Compression Testing of Aircraft Engine Cylinders, in Advisory 
Circular 43.13-1B, Change 1, dated September 27, 2001. Also, SAP 
Service Bulletin B08-01, dated January 10, 2008, contains 
information on cylinder differential pressure tests.
    (i) If the cylinder pressure gage reads below 60 pounds per-
square inch, apply a 2 percent soapy solution to the side of the 
leaking cylinder.
    (ii) If you see air leakage and bubbles on the side of the 
cylinder, near the head-to-cylinder interface, replace the cylinder 
assembly.
    (g) Thereafter, repeat the cylinder visual inspections and 
compression tests within 50 flight hours time-since-last inspection 
(TSLI) until the cylinders reach their time-before-overhaul (TBO) 
limits.

Replacing SAP Cylinder Assemblies

    (h) For TCM IO-520, TSIO-520, and IO-550 series engines with SAP 
cylinder assemblies, P/Ns SA52000-A1, SA52000-A20P, SA52000-A21P, 
SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-A20P, installed, 
that have accumulated or exceeded their respective TBO hours, 
replace the cylinder assembly within 25 flight hours TIS after the 
effective date of this AD.

Prohibition Against Installing Certain P/N SAP Cylinder Assemblies

    (i) After the effective date of this AD, do not install any SAP 
cylinder assembly, P/Ns SA52000-A1, SA52000-A20P, SA52000-A21P, 
SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-A20P, in any 
engine.

Alternative Methods of Compliance

    (j) The Manager, Special 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.

[[Page 19775]]

Related Information

    (k) FAA Advisory Circular 43.13-1B, Change 1, dated September 
27, 2001, and SAP service bulletin B08-01, dated January 10, 2008, 
contain information on cylinder differential pressure tests.
    (l) Contact Tausif Butt, Aerospace Engineer, Special 
Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76137-4298; e-mail: tausif.butt@faa.gov; 
telephone (817) 222-5195; fax (817) 222-5785, for more information 
about this AD.

    Issued in Burlington, Massachusetts, on April 4, 2008.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E8-7711 Filed 4-10-08; 8:45 am]

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