Airworthiness Directives; Leonardo S.p.a. Helicopters, 11404-11407 [2021-03658]

Agencies

• Federal Aviation Administration
• DEPARTMENT OF TRANSPORTATION

[Federal Register Volume 86, Number 36 (Thursday, February 25, 2021)]
[Rules and Regulations]
[Pages 11404-11407]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2021-03658]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2020-0503; Product Identifier 2018-SW-006-AD; Amendment 
39-21386; AD 2021-02-03]
RIN 2120-AA64


Airworthiness Directives; Leonardo S.p.a. Helicopters

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Leonardo S.p.a. (Leonardo) Model AW189 helicopters. This AD 
requires various repetitive inspections of the

[[Page 11405]]

main rotor (MR) damper. This AD was prompted by reports of in-service 
MR damper failures and the development of an improved MR damper. This 
condition, if not corrected, could lead to loss of the lead-lag damping 
function of the MR blade, possibly resulting in damage to adjacent 
critical rotor components and subsequent loss control of the 
helicopter. The actions of this AD are intended to address the unsafe 
condition on these products.

DATES: This AD is effective April 1, 2021.
    The Director of the Federal Register approved the incorporation by 
reference of certain documents listed in this AD as of April 1, 2021.

ADDRESSES: For service information identified in this final rule 
contact Leonardo S.p.A. Helicopters, Emanuele Bufano, Head of 
Airworthiness, Viale G.Agusta 520, 21017 C.Costa di Samarate (Va) 
Italy; telephone +39-0331-225074; fax +39-0331-229046; or at https://www.leonardocompany.com/en/home. You may view the referenced service 
information at the FAA, Office of the Regional Counsel, Southwest 
Region, 10101 Hillwood Pkwy., Room 6N-321, Fort Worth, TX 76177. It is 
also available on the internet at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2020-0503.

Examining the AD Docket

    You may examine the AD docket on the internet at https://www.regulations.gov by searching for and locating Docket No. FAA-2020-
0503; or in person at Docket Operations between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays. The AD docket contains 
this AD, the European Aviation Safety Agency (now European Union 
Aviation Safety Agency) (EASA) AD, any service information that is 
incorporated by reference, any comments received, and other 
information. The street address for Docket Operations is U.S. 
Department of Transportation, Docket Operations, M-30, West Building 
Ground Floor, Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 
20590.

FOR FURTHER INFORMATION CONTACT: Matt Fuller, AD Program Manager, 
Operational Safety Branch, Airworthiness Products Section, General 
Aviation & Rotorcraft Unit, FAA, 10101 Hillwood Pkwy., Fort Worth, TX 
76177; telephone 817-222-5110; email [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to Leonardo Model AW189 
helicopters with MR damper part number (P/N) 4F6220V00251 installed. 
The NPRM published in the Federal Register on May 20, 2020 (85 FR 
30664). The NPRM proposed to require reducing the installation torque 
of the nuts on the bolts attaching the MR damper to the MR hub. The 
NPRM also proposed to require, at specified intervals, replacing the 
affected MR damper; dye penetrant or eddy current inspecting the rod 
end and body end of each MR damper for a crack, visually inspecting the 
rod end and body end of each MR damper for a crack, and replacing any 
cracked MR damper. For certain helicopters, the NPRM also proposed to 
require inspecting each rod end and body end bearing for rotation, and 
replacing the rod end or MR damper as applicable if there is any 
rotation; inspecting the lag damper broached ring nut for damage, 
correct engagement, and alignment and removing the rod end and broached 
ring nut from service if any of those conditions exist. For all 
helicopters, the NPRM proposed to require, at specified intervals, 
inspecting the bearing friction torque of each MR damper body end and 
rod end, and replacing the MR damper if the torque value exceeds 30.0 
Nm (265.5 lb in); inspecting the MR damper anti-rotation block for wear 
and replacing the anti-rotation block if there is wear beyond 
acceptable limits; and replacing each special washer P/N 3G6220A05051 
with special washer P/N 3G6220A05052. For certain MR dampers, the NPRM 
proposed to require inspecting the broached ring for damage and 
alignment, removing the broached ring from service if there is damage, 
and replacing the broached ring if the rod end and broached ring cannot 
be aligned. Finally, the NPRM proposed to require inspecting certain 
serial-numbered MR dampers for correct torque of the broached ring 
prior to installation on any helicopter. The proposed requirements were 
intended to detect a crack in an MR damper, which if not detected and 
corrected, could lead to loss of the lead-lag damping function of the 
MR blade, resulting in damage of the MR damper, detachment of the MR 
damper in-flight, and subsequent loss of control of the helicopter.
    The NRPM was prompted by EASA AD No. 2016-0145R1, dated January 17, 
2018 (EASA AD 2016-0145R1), issued by EASA, which is the Technical 
Agent for the Member States of the European Union, to correct an unsafe 
condition for Leonardo Model AW189 helicopters with MR damper P/N 
4F6220V00251 installed. EASA advises that a MR damper failed, which 
resulted in complete seizure of the body end lug and an in-flight 
disconnection of the damper. EASA states that a combination of factors 
may have contributed to the MR damper disconnection, and that this 
condition could result in loss of the lead-lag damping function of the 
MR blade, damage to adjacent critical rotor components, and subsequent 
reduced control of the helicopter. The contributing factors include 
cracks, slippage marks, damaged broach ring teeth, and loss of torque.
    According to EASA, the AW189 MR damper is a similar design to the 
MR dampers installed on Model AW139 helicopters, where multiple MR 
damper failures have been reported involving the body end lug, the eye 
end lug, and the rod end. To correct this condition, EASA issued a 
series of superseded and revised ADs to require repetitive inspections 
of certain MR dampers, and similar corrective actions as those for 
Model AW139 helicopters. EASA AD 2016-0145R1 requires various one-time 
and repetitive inspections of the MR damper, a torque check of the body 
end, and replacing any MR damper with a crack or that fails the torque 
check. EASA AD 2016-0145R1 also allows installation of a new MR damper, 
P/N 8G6220V00151, as an optional terminating action for the repetitive 
inspections.

Comments

    The FAA gave the public the opportunity to participate in 
developing this final rule, but the FAA did not receive any comments on 
the NPRM or on the determination of the cost to the public.

FAA's Determination

    These helicopters have been approved by EASA and are approved for 
operation in the United States. Pursuant to the FAA's bilateral 
agreement with the European Union, EASA has notified the FAA of the 
unsafe condition described in its AD. The FAA is issuing this AD after 
evaluating all of the information provided by EASA and determining the 
unsafe condition exists and is likely to exist or develop on other 
helicopters of the same type design and that air safety and the public 
interest require adopting these AD requirements as proposed.

Differences Between This AD and the EASA AD

    The EASA AD requires contacting the manufacturer under certain 
conditions, while this AD does not.

[[Page 11406]]

Related Service Information Under 1 CFR Part 51

    The FAA reviewed Finmeccanica Bollettino Tecnico No. 189-080, 
Revision A, dated July 15, 2016, which contains procedures for visual 
and dye penetrant inspections of the MR damper for cracks and for 
verifying the torque of the damper body ends.
    The FAA also reviewed Leonardo Helicopters Alert Service Bulletin 
No. 189-102, Revision A, dated December 21, 2017, which contains 
procedures for installing an MR damper with reduced torque values and 
specifies replacing MR damper P/N 4F6220V00251 with new MR damper P/N 
8G6220V00151.
    This service information is reasonably available because the 
interested parties have access to it through their normal course of 
business or by the means identified in the ADDRESSES section.

Other Related Service Information

    The FAA reviewed Finmeccanica Bollettino Tecnico No. 189-069, dated 
February 12, 2016, which contains procedures for installing a special 
washer on the MR damper rod end, modifying the installation torque of 
the MR damper, and inspecting the rod end bearings.

Costs of Compliance

    The FAA estimates that this AD affects 3 helicopters of U.S. 
Registry. The FAA estimates that operators may incur the following 
costs in order to comply with this AD. Labor costs are estimated at $85 
per work-hour.
    Adjusting the tightening torque takes about 10 work-hours, for an 
estimated cost of $850 per helicopter and $2,550 for the U.S. fleet.
    Replacing an MR damper takes about 2 work-hours, and parts cost 
about $18,000, for an estimated cost of $18,170 per MR damper.
    Performing a dye penetrant or eddy current inspection of the MR 
damper takes about 8 work-hours, for an estimated cost of $680 per 
helicopter and $2,040 for the U.S fleet.
    Visually inspecting the rod ends and body ends takes about 0.5 
hour, for an estimated cost of $43 per helicopter and $129 for the U.S. 
fleet, per inspection cycle.
    Inspecting the rod ends and body ends for bearing rotation takes 
about 0.5 hour, for an estimated cost of $43 per helicopter and $129 
for the U.S. fleet, per inspection cycle.
    Inspecting the broached ring nut takes about 0.5 hour, for an 
estimated cost of $43 per helicopter and $129 for the U.S. fleet, per 
inspection cycle.
    Inspecting for bearing friction takes about 2 hours, for an 
estimated cost of $170 per helicopter and $510 for the U.S fleet, per 
inspection cycle.
    Inspecting the broached ring teeth for proper alignment and 
applying torque takes about 8 work-hours, for an estimated cost of $680 
per helicopter and $2,040 for the U.S fleet.
    Replacing a rod end takes about 3 work-hours and parts cost about 
$500, for an estimated cost of $755 per rod end.
    Replacing a broached ring takes about 3 work-hours and parts cost 
about $100, for an estimated cost of $355 per broached ring.
    Replacing a broached ring nut takes about 3 work-hours and parts 
cost about $125, for an estimated cost of $380 per broached ring nut.
    Replacing an anti-rotation block takes about 3 work-hours and parts 
cost about $50, for an estimated cost of $305 per anti-rotation block.

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.
    The FAA is 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 helicopters identified in this rulemaking action.

Regulatory Findings

    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 this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Will not affect intrastate aviation in Alaska, 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.

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:

2021-02-03 Leonardo S.p.a: Amendment 39-21386; Docket No. FAA-2020-
0503; Product Identifier 2018-SW-006-AD.

(a) Applicability

    This airworthiness directive (AD) applies to Leonardo S.p.a. 
Model AW189 helicopters, certificated in any category, with a main 
rotor (MR) damper part number (P/N) 4F6220V00251 installed.

(b) Unsafe Condition

    This AD defines the unsafe condition as a crack in an MR damper, 
which if not detected and corrected, could lead to loss of the lead-
lag damping function of the MR blade, resulting in damage of the MR 
damper, detachment of the MR damper in-flight, and subsequent loss 
of control of the helicopter.

(c) Effective Date

    This AD becomes effective April 1, 2021.

(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 10 hours time-in-service (TIS), reduce the torque of 
the nut on the bolt attaching each MR damper to the MR hub by 
following paragraphs 4 through 7 of the Accomplishment Instructions, 
Part I, of Leonardo Helicopters Alert Service Bulletin No. 189-102, 
Revision A, dated December 21, 2017 (ASB 189-102).
    (2) Within 30 hours TIS or before the MR damper body end (body 
end) accumulates 500 hours TIS, whichever occurs later, and 
thereafter at intervals not to exceed 500 hours TIS, replace the MR 
damper.
    (3) Within 30 hours TIS, before the MR damper accumulates 300 
hours TIS, or within 300 hours TIS since the last overhaul, 
whichever occurs later, dye penetrant inspect using a 5X power 
magnifying glass or eddy current inspect each MR damper rod end (rod

[[Page 11407]]

end) and body end for a crack in the areas depicted in Figure 2 of 
Finmeccanica Bollettino Tecnico No. 189-080, Revision A, dated July 
15, 2016 (BT 189-080).
    (i) If there is a crack on the body end, before further flight, 
replace the MR damper.
    (ii) If there is a crack on the rod end, before further flight, 
replace the rod end and, within 300 hours TIS, dye penetrant or eddy 
current inspect the rod end for a crack as described in paragraph 
(e)(3) of this AD.
    (iii) If there are no cracks, before further flight, mark the 
rod end and body end with a dot of black polyurethane paint as shown 
in Figure 13 of BT 189-080.
    (iv) Thereafter, before the first flight of each day, using a 
mirror and a magnifying glass visually inspect each rod end and body 
end for a crack in the areas shown in Figure 14 of BT 189-080. If 
there is a crack in the rod end, before further flight, replace the 
rod end. If there is a crack on the body end, before further flight, 
replace the MR damper.
    (4) Within the compliance times listed in paragraphs (e)(4)(i) 
and (ii) of this AD, inspect each rod end bearing and body end for 
bearing rotation in the damper seat. An example of rotation 
(misaligned slippage marks) is shown in Figure 4 of BT 189-080. If 
there is any bearing rotation in the rod end, before further flight, 
replace the rod end. If there is any bearing rotation in the body 
end, before further flight, replace the MR damper.
    (i) For MR dampers that have accumulated less than 300 hours TIS 
since new or since the last overhaul, within 30 hours TIS and 
thereafter at intervals not to exceed 10 hours TIS.
    (ii) For MR dampers that have accumulated 300 or more hours TIS 
since new or since the last overhaul, within 5 hours TIS and 
thereafter before the first flight of each day.
    (5) For helicopters with an MR damper with a serial number (S/N) 
MCR0001 through MCR0154 and MCR0174 through MCR0195, within 30 hours 
TIS and thereafter at intervals not to exceed 20 hours TIS until the 
MR damper has accumulated 600 hours TIS, visually inspect each MR 
damper broached ring nut for broken teeth, proper engagement, and 
alignment as depicted in Figure 5 and shown in Figures 6, 7, and 8 
of BT 189-080. If there is a broken tooth, improper engagement, or 
misalignment of the broached ring nut, before further flight, remove 
from service the rod end and broached ring nut.
    (6) Within 50 hours TIS and thereafter at intervals not to 
exceed 100 hours TIS:
    (i) Rotate the body end around the damper axis to put it near 
the middle position and determine the bearing friction torque value 
of the body end, using as a reference Figure 11 of BT 189-080.

    Note 1 to Paragraph (e)(6)(i):  Applying too much force while 
rotating the body end around the damper axis may cause damage.

    (A) If the torque value of the body end is more than 30.0 Nm 
(265.5 in lb), before further flight, replace the MR damper.
    (B) If the torque value of the body end is 30.0 Nm (265.5 in lb) 
or less, determine the bearing friction torque value of each rod 
end, using as a reference Figure 11 of BT 189-080. If the torque 
value of the rod end is more than 30.0 Nm (265.5 in lb), before 
further flight, replace the rod end.
    (ii) Inspect each MR damper anti-rotation block for wear by 
following paragraphs 4.3 through 4.3.6 of the Compliance 
Instructions, Part VI, of BT 189-080. If there is wear, before 
further flight, replace the MR damper anti-rotation block.
    (7) Within 50 hours TIS:
    (i) On each MR damper, replace special washer P/N 3G6220A05051 
with special washer P/N 3G6220A05052.
    (ii) For helicopters with an MR damper with a S/N MCR0001 
through MCR0041, MCR0043, MCR0045 through MCR0151, MCR0153 through 
MCR0157, MCR0159 through MCR 0179, and MCR0185 through MCR0370; and 
for MR dampers with a rod end P/N M006-01H004-045 or P/N M006-
01H004-053 installed, do the following:
    (A) Inspect each broached ring for wear, bent teeth, missing 
teeth, and stripped threads. Pay particular attention to the four 
pins that engage the piston grooves. If there is any wear or damage 
to the broached ring, before further flight, remove from service the 
broached ring. An example of an acceptable broached ring is shown in 
Figure 4, Annex A, of BT 189-080.
    (B) Align each rod end and broached ring by applying a torque of 
60 Nm (531 in lb) to 80 Nm (708 in lb). If the rod end and broached 
ring cannot be aligned, before further flight, replace the broached 
ring.
    (8) Except for MR dampers with a S/N MCR0042, MCR0044, MCR0152, 
MCR0158, and MCR0180 through MCR0184, do not install an MR damper P/
N 4F6220V00251 on any helicopter unless the MR damper has passed the 
requirements in paragraph (e)(7)(ii) of this AD.

(f) Credit For Previous Actions

    (1) Actions accomplished before the effective date of this AD in 
accordance with the Compliance Instructions, Part II, of 
Finmeccanica Bollettino Tecnico No. 189-069, dated February 12, 2016 
(BT 189-069), are considered acceptable for compliance with the 
corresponding actions in paragraph (e)(7)(i) of this AD.
    (2) Actions accomplished before the effective date of this AD in 
accordance with the Compliance Instructions, Part III, of BT 189-
069, are considered acceptable for compliance with the corresponding 
actions in paragraph (e)(7)(ii) of this AD.

(g) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Rotorcraft Standards Branch, FAA, may approve 
AMOCs for this AD. Send your proposal to: Matt Fuller, AD Program 
Manager, Operational Safety Branch, Airworthiness Products Section, 
General Aviation & Rotorcraft Unit, FAA, 10101 Hillwood Pkwy., Fort 
Worth, TX 76177; telephone 817-222-5110; email [email protected].
    (2) For operations conducted under a 14 CFR part 119 operating 
certificate or under 14 CFR part 91, subpart K, the FAA suggests 
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

    (1) Finmeccanica Bollettino Tecnico No. 189-069, dated February 
12, 2016, which is not incorporated by reference, contains 
additional information about the subject of this AD. For service 
information identified in this AD, contact Leonardo S.p.A. 
Helicopters, Emanuele Bufano, Head of Airworthiness, Viale G.Agusta 
520, 21017 C.Costa di Samarate (Va) Italy; telephone +39-0331-
225074; fax +39-0331-229046; or at https://www.leonardocompany.com/en/home. You may view the referenced service information at the FAA, 
Office of the Regional Counsel, Southwest Region, 10101 Hillwood 
Pkwy., Room 6N-321, Fort Worth, TX 76177.
    (2) The subject of this AD is addressed in European Aviation 
Safety Agency (now European Union Aviation Safety Agency) (EASA) No. 
2016-0145R1, dated January 17, 2018. You may view the EASA AD on the 
internet at https://www.regulations.gov in Docket No. FAA-2020-0503.

(i) Subject

    Joint Aircraft Service Component (JASC) Code: 6200, Main Rotor 
System.

(j) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference of the service information listed in this 
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Finmeccanica Bollettino Tecnico No. 189-080, Revision A, 
dated July 15, 2016.
    (ii) Leonardo Helicopters Alert Service Bulletin No. 189-102, 
Revision A, dated December 21, 2017.
    (3) For service information identified in this AD, contact 
Leonardo S.p.a. Helicopters, Emanuele Bufano, Head of Airworthiness, 
Viale G. Agusta 520, 21017 C. Costa di Samarate (Va) Italy; 
telephone +39-0331-225074; fax +39-0331-229046; or at https://www.leonardocompany.com/en/home.
    (4) You may view this service information at the FAA, Office of 
the Regional Counsel, Southwest Region, 10101 Hillwood Pkwy., Room 
6N-321, Fort Worth, TX 76177. For information on the availability of 
this material at the FAA, call 817-222-5110.
    (5) You may view this service information that is incorporated 
by reference at the National Archives and Records Administration 
(NARA). For information on the availability of this material at 
NARA, email [email protected], or go to: https://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued on January 6, 2021.
Lance T. Gant,
Director, Compliance & Airworthiness Division, Aircraft Certification 
Service.
[FR Doc. 2021-03658 Filed 2-24-21; 8:45 am]
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