Document ID: FAA-2016-9291-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Sikorsky Aircraft Corporation Helicopters
Posted Date: 2017-03-27T04:00Z

[Federal Register Volume 82, Number 57 (Monday, March 27, 2017)]
[Rules and Regulations]
[Pages 15120-15123]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2017-05967]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2016-9291; Directorate Identifier 2016-SW-004-AD; 
Amendment 39-18840; AD 2017-07-02]
RIN 2120-AA64

Airworthiness Directives; Sikorsky Aircraft Corporation 
Helicopters

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: We are adopting a new airworthiness directive (AD) for 
Sikorsky Aircraft Corporation (Sikorsky) Model 269D and Model 269D 
Configuration A helicopters. This AD requires reducing the life limit 
of and inspecting certain drive shafts. This AD is prompted by four 
incidents involving failure of a drive shaft. The actions specified by 
this AD are intended to prevent the unsafe condition on these products.

DATES: This AD becomes effective April 11, 2017.
    We must receive comments on this AD by May 26, 2017.

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 by searching for and locating Docket No. FAA-2016-
9291; 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 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 final rule, contact 
Sikorsky Aircraft Corporation, Customer Service Engineering, 124 Quarry 
Road, Trumbull, CT 06611; telephone 1-800-Winged-S or 203-416-4299; 
email: wcs_cust_service_eng.gr-sik@lmco.com. You may review the 
referenced service information at the FAA, Office of the Regional 
Counsel, Southwest Region, 10101 Hillwood Pkwy., Room 6N-321, Fort 
Worth, TX 76177.

FOR FURTHER INFORMATION CONTACT: Michael Schwetz, Aviation Safety 
Engineer, Boston Aircraft Certification Office, Engine & Propeller 
Directorate, FAA, 1200 District Avenue, Burlington, Massachusetts 
01803; telephone (781) 238-7761; email michael.schwetz@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

[[Page 15121]]

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

    We are adopting a new AD for Sikorsky Model 269D and Model 269D 
Configuration A helicopters with KAflex drive shaft (engine side) part 
number (P/N) SKCP2738-7 and KAflex drive shaft (pulley side) P/N 
SKCP2738-5 installed. This AD is prompted by four incidents involving 
failure of the engine side drive shaft. Three incidents experienced 
loss of rotor drive resulting in forced landings. The fourth incident 
resulted in vibration during flight prompting an immediate landing. A 
fractured engine side drive shaft was evident in each incident. 
Investigations revealed compression of the rubber engine mounts may 
lead to loss of alignment between the lower pulley shaft and the engine 
output shaft, resulting in fracture of the engine side drive shaft. 
Additionally, it has been discovered that increased cyclic torsional 
loading was inaccurately applied in previous fatigue analysis, making 
it necessary to reduce the life limit.
    Accordingly, this AD requires reducing the life limit of the engine 
side drive shaft and pulley side drive shaft to 6,000 hours time-in-
service (TIS) for Model 269D helicopters and 1,200 hours TIS for Model 
269D Configuration A helicopters. If the drive shaft is interchanged or 
has ever been interchanged between the two model configurations, this 
AD requires using the lower life limit of 1,200 hours TIS. This AD also 
requires performing several inspections of the drive shaft within 25 
hours TIS and, depending on the results of these inspections, replacing 
both the engine side and pulley side drive shafts.
    The actions specified by this AD are intended to prevent failure of 
the drive shaft, loss of rotor drive, and subsequent loss of control of 
the helicopter. Additional inspections at longer intervals may also be 
necessary. We plan to publish a notice of proposed rulemaking to give 
the public an opportunity to comment on those long-term requirements.

Record of Ex Parte Communication

    In preparation of AD actions such as notices of proposed rulemaking 
and immediately adopted final rules, it is the practice of the FAA to 
obtain technical information and information on the operational and 
economic impact from design approval holders and aircraft operators. We 
discussed certain aspects of this AD by email and telephone with 
Sikorsky. A copy of each email contact and a discussion of each 
telephone contact can be found in the rulemaking docket. For 
information on locating the docket, see ``Examining the AD Docket.''

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 products of the same type designs.

Related Service Information

    We reviewed Appendix B to Sikorsky S-330 Model 269D Helicopter 
Basic Handbook of Maintenance Instructions No. CSP-D-2, dated February 
1, 1993, and revised October 15, 2014; and Appendix B to Sikorsky S-333 
Model 269D Config. ``A'' Helicopter Basic Handbook of Maintenance 
Instructions No. CSP-D-9, dated July 20, 2001, and revised October 15, 
2014. This service information specifies repetitive inspection 
procedures, overhaul and retirement schedules, and weight and balance 
procedures. The Airworthiness Limitations section, which is included in 
this service information, contains the life limits for drive shaft 
assembly P/Ns SKCP2738-5 and SKCP2738-7.
    We also reviewed Sikorsky 269D Helicopter Alert Service Bulletin 
DB-052, Basic Issue, dated January 16, 2014, which distributes the 
service life reduction information and implements a new 1,200-hour 
overhaul inspection for drive shaft assembly P/Ns SKCP2738-3, SKCP2738-
5, and SKCP2738-7.

AD Requirements

    This AD requires, before further flight:
     Removing from service any engine side drive shaft P/N 
SKCP2738-7 and pulley side drive shaft P/N SKCP2738-5 that has reached 
or exceeded its new life limit as follows:
    [cir] 6,000 hours TIS for Model 269D helicopters;
    [cir] 1,200 hours TIS for Model 269D Configuration A helicopters; 
and
    [cir] 1,200 hours TIS if the parts have ever been interchanged 
between the two model configurations.
    This AD also requires, within 25 hours TIS:
     Inspecting the KAflex drive shaft alignment.
     Inspecting the engine side and pulley side drive shafts 
for a crack, any corrosion or pitting, a nick, a dent, and a scratch.
     Inspecting each bolted joint (joint) for movement.
     Inspecting each joint for fretting corrosion and each 
frame and mount bolt torque stripe for movement.
     Inspecting each joint for fretting, for a crack around 
both the bolt head and washer side, and around the nut and washer side, 
and each inside and outside corner radii and radii edges on both sides 
of each frame for a crack.
    If the drive shaft fails any of the above inspections, this AD 
requires replacing both the engine side and pulley side drive shafts 
before further flight.
    Lastly, this AD requires within 25 hours TIS and thereafter at 
intervals not to exceed 25 hours TIS:
     Inspecting the lower pulley to engine alignment, and if 
there is any interference with the rotation of the belt drive alignment 
tool, adjusting the engine elevation alignment before further flight.
    This AD also specifies installing KAflex engine side coupling 
assembly P/N SKCP2738-9 and KAflex pulley side coupling assembly P/N 
SKCP2738-101 as an optional terminating action for the requirements of 
this AD.

Differences Between This AD and the Service Information

    The Sikorsky service information specifies a drive shaft assembly 
service life of 3,000 hours TIS with a 1,200 hour overhaul inspection 
for Model 269D Configuration A helicopters, while this AD specifies a 
service life of 1,200 hours TIS.
    This AD specifies several inspections with a compliance time of 25 
hours TIS that are currently recurring inspections at 100-hour or 400-
hour intervals in Sikorsky's service information.
    The Sikorsky service information specifies different inspection 
procedures if there is spline engagement interference or resistance 
while inspecting the drive shaft alignment. This AD specifies replacing 
both the engine side and pulley side drive shafts if there is any 
spline engagement interference or resistance.
    The Sikorsky service information specifies inspecting the working

[[Page 15122]]

fastener condition without any specific succeeding action regarding the 
inspection. This AD specifies replacing both the engine side and pulley 
side drive shafts if there is any joint movement.
    The Sikorsky service information specifies returning the drive 
shaft assembly to Sikorsky if there is fretting dust or red metallic 
residue at a joint. This AD specifies replacing both the engine side 
and pulley side drive shafts if there is any fretting corrosion.

Interim Action

    We consider this AD interim action. If final action is later 
identified, we might consider further rulemaking then.

Costs of Compliance

    We estimate that this AD affects 18 helicopters of U.S. Registry. 
We estimate that operators may incur the following costs to comply with 
this AD. Labor costs are estimated at $85 per work-hour. Removing the 
engine side and pulley side drive shafts that have reached the new life 
limit will take about 4 work-hours for a cost of $340 per helicopter. 
Inspecting the drive shaft alignment will take about 1 work-hour for a 
cost of $85 per helicopter and $1,530 for the U.S. fleet. Inspecting 
the drive shafts for damage will take about 1 work-hour for an 
estimated cost of $85 per helicopter and $1,530 for the U.S. fleet. 
Inspecting the joints will take about 1 work-hour for an estimated cost 
of $85 per helicopter and $1,530 for the U.S. fleet. Replacing the 
engine side and pulley side drive shafts, if required, will take about 
8 work-hours and parts will cost about $20,000, for an estimated cost 
of $20,680 per helicopter. Inspecting the lower pulley to engine 
alignment will take about 0.5 work-hour for an estimated cost of $43 
per helicopter and $774 for the U.S. fleet per inspection cycle. 
Adjusting the engine elevation alignment will take about 0.5 work-hour 
for an estimated cost of $43 per helicopter.

FAA's Justification and Determination of the Effective Date

    Providing an opportunity for public comments prior to adopting 
these AD requirements would delay implementing the safety actions 
needed to correct this known unsafe condition. Therefore, we find that 
the risk to the flying public justifies waiving notice and comment 
prior to the adoption of this rule because some of the required 
corrective actions must be completed before further flight.
    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 contrary to 
the public interest 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):

2017-07-02 Sikorsky Aircraft Corporation (Sikorsky): Amendment 39-
18840; Docket No. FAA-2016-9291; Directorate Identifier 2016-SW-004-
AD.

(a) Applicability

    This AD applies to Sikorsky Model 269D and Model 269D 
Configuration A helicopters with a KAflex engine side drive shaft 
part number (P/N) SKCP2738-7 and KAflex pulley side drive shaft P/N 
SKCP2738-5 installed, certificated in any category.

(b) Unsafe Condition

    This AD defines the unsafe condition as failure of a drive 
shaft. This condition could result in loss of rotor drive and 
subsequent loss of control of the helicopter.

(c) Effective Date

    This AD becomes effective April 11, 2017.

(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) Before further flight:
    (i) For Model 269D helicopters, remove from service any KAflex 
engine side drive shaft P/N SKCP2738-7 and any KAflex pulley side 
drive shaft P/N SKCP2738-5 that has 6,000 or more hours time-in-
service (TIS). Thereafter, remove from service any KAflex engine 
side drive shaft P/N SKCP2738-7 and any KAflex pulley side drive 
shaft P/N SKCP2738-5 before accumulating 6,000 hours TIS.
    (ii) For Model 269D Configuration A helicopters, remove from 
service any KAflex engine side drive shaft P/N SKCP2738-7 and any 
KAflex pulley side drive shaft P/N SKCP2738-5 that has 1,200 or more 
hours TIS. Thereafter, remove from service any KAflex engine side 
drive shaft P/N SKCP2738-7 and any KAflex pulley side drive shaft P/
N SKCP2738-5 before accumulating 1,200 hours TIS.
    (iii) If interchanged between Model 269D and Model 269D 
Configuration A helicopters, remove from service any KAflex engine 
side drive shaft P/N SKCP2738-7 and any KAflex pulley side drive 
shaft P/N SKCP2738-5 that has 1,200 or more hours TIS. Thereafter, 
if interchanged between Model 269D and Model 269D Configuration A 
helicopters, remove from service any KAflex engine side drive shaft 
P/N SKCP2738-7 and any KAflex pulley side drive shaft P/N SKCP2738-5 
before accumulating 1,200 hours TIS.

[[Page 15123]]

    (2) Within 25 hours TIS:
    (i) Remove the drive shaft to adapter bolt and inspect the drive 
shaft alignment. Engage and disengage the splines a minimum of 3 
times by sliding the engine power output shaft in and out of the 
engine. Inspect the alignment at each 90[deg] interval by rotating 
the lower pulley with the power shaft disengaged. Determine whether 
the adapter slides on and off the drive shaft splines without spline 
engagement interference or resistance along the entire length of 
movement. If there is any spline engagement interference or 
resistance, before further flight, replace both the engine side and 
pulley side drive shafts.
    (ii) Inspect each drive shaft for a crack, any corrosion or 
pitting, a nick, a dent, and a scratch. If there is a crack, any 
corrosion or pitting, a nick, a dent, or a scratch that exceeds 
allowable limits, before further flight, replace both the engine 
side and pulley side drive shafts.
    (iii) Remove the engine side drive shaft and pulley side drive 
shaft and perform the following:
    (A) Inspect each flex frame (frame) bolted joint (joint) for 
movement by hand. If there is any movement, before further flight, 
replace both the engine side and pulley side drive shafts.
    (B) Visually inspect each joint for fretting corrosion (which 
might be indicated by metallic particles) and each frame and mount 
bolt torque stripe for movement. If there is any fretting corrosion 
or torque stripe movement, before further flight, replace both the 
engine side and pulley side drive shafts.
    (C) Using a 10x or higher power magnifying glass, visually 
inspect each joint for fretting and for a crack around the bolt head 
and washer side, and around the nut and washer side. Also inspect 
both sides of each frame for a crack on the inside and outside 
corner radii and radii edge (four). If there is any fretting, a 
crack at any point over the full circumference (360[deg]) of the 
bolt head and washer side or the nut and washer side, or a crack in 
any of the corner radii edges, before further flight, replace both 
the engine side and pulley side drive shafts.
    (iv) Using a belt drive alignment tool 269T3303-003, inspect the 
lower pulley to engine alignment by engaging the tool on the drive 
shaft and inserting in the lower pulley bore. Rotate the tool 
360[deg] around the drive shaft and inspect for interference. If 
there is any interference with the rotation of the tool, before 
further flight, adjust the engine elevation alignment to eliminate 
the interference.
    (3) Thereafter, at intervals not to exceed 25 hours TIS, repeat 
the actions specified in paragraph (e)(2)(iv) of this AD.
    (4) As an optional terminating action to the repetitive 
inspections in this AD, you may install KAflex engine side drive 
shaft P/N SKCP2738-9 and KAflex pulley side drive shaft P/N 
SKCP2738-101.

(f) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Boston Aircraft Certification Office, FAA, may 
approve AMOCs for this AD. Send your proposal to: Michael Schwetz, 
Aviation Safety Engineer, Boston Aircraft Certification Office, 
Engine & Propeller Directorate, FAA, 1200 District Avenue, 
Burlington, Massachusetts 01803; telephone (781) 238-7761; email 
michael.schwetz@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.

(g) Additional Information

    Sikorsky 269D Helicopter Alert Service Bulletin DB-052, Basic 
Issue, dated January 16, 2014; Appendix B of Sikorsky S-330 Model 
269D Helicopter Basic Handbook of Maintenance Instructions, No. CSP-
D-2, dated February 1, 1993, and revised October 15, 2014; and 
Appendix B of Sikorsky S-330 Model 269D Config. ``A'' Helicopter 
Basic Handbook of Maintenance Instructions, No. CSP-D-9, dated July 
20, 2001, and revised October 15, 2014; which are not incorporated 
by reference, contain additional information about the subject of 
this AD. For service information identified in this AD, contact 
Sikorsky Aircraft Corporation, Customer Service Engineering, 124 
Quarry Road, Trumbull, CT 06611; telephone 1-800-Winged-S or 203-
416-4299; email: wcs_cust_service_eng.gr-sik@lmco.com. You may 
review this service information at the FAA, Office of the Regional 
Counsel, Southwest Region, 10101 Hillwood Pkwy, Room 6N-321, Fort 
Worth, TX 76177.

 (h) Subject

    Joint Aircraft Service Component (JASC) Code: 6310, Engine/
Transmission Coupling.

    Issued in Fort Worth, Texas, on March 20, 2017.
Scott A. Horn,
Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 2017-05967 Filed 3-24-17; 8:45 am]
 BILLING CODE 4910-13-P