AIRWORTHINESS DIRECTIVE
For the reasons set out in the background section, the CASA delegate whose signature appears below revokes Airworthiness Directive (AD) AD/BAL/3 Amdt 3 and issues the following AD under subregulation 39.1 (1) of CAR 1998. The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.
Hot Air Balloons
AD/BAL/3
Amdt 4
LP Gas Cylinders 7/2002
Applicability: All LPG fuel cylinders for use in hot air balloons.
Requirement: 1. Inspect in accordance with the requirements of Australian Standard AS 2030.1- 1999. Where any defect or suspected defect as defined in Table 6.1 of AS 2337.1-1999 is found, hydrostatic proof testing is required.
2. For cylinders for which a service life limitation is specified by the cylinder specification and/or manufacturer, retire the cylinder from service and destroy.
Notes:
- Previous versions of AS 2030.1 stated that they were not applicable to cylinders used in aircraft. AS 2030.1-1999, makes clear that it is applicable as a reference made in a direction pursuant to the Civil Aviation Regulations.
2. A “certificated test station” is a test station that has been certified in accordance with the requirements of AS 2337.1. Further, an endorsement of compliance with AS 2030.1-1999 made by such a certificated test station is acceptable as an entry or reference in CASA approved documents for the purpose of inspection of the cylinder only.
Such an endorsement or certification is not an endorsement for correct assembling of a cylinder assembly, nor the installation of such an assembly into a balloon; e.g. there are additional requirements such as AD/BAL/14.
An authorised person must still certify on a balloon's approved Aircraft Log Book as to serviceability and suitability prior to use of the cylinder/s.
3. Section 8.2 and 8.3 of AS 2030.1-1999 are of particular importance. These sections require that any tests or inspections called up by the cylinder specification and/or manufacturer must be complied with in conjunction with the tests and inspections listed in AS 2030.1-1999; e.g. certain American and UK cylinder specifications, and/or manufacturers, require a hydrostatic pressure test every 10 years; in which case the hydrostatic test must be carried out.
4. It is a requirement of the various State OH&S and Gas laws that only cylinders that have been inspected in accordance with AS 2030.1-1999 can be refilled. These laws are applicable to the cylinders used in hot air ballooning, and the Authority has no jurisdiction over this aspect. Hence, it is possible for foreign sourced cylinders to be acceptable to the Authority for the purpose of a Type Certificate, but not be in compliance with the law/s of the State/s.
In such circumstances, while it may be legitimate to use such cylinders for an aviation purpose, they may not be refilled under the terms of a State's regulatory requirement.
CASA has no responsibility whatsoever for such matters and the owner/CofR holder is responsible for seeking compliance with the law/s of the State/s.
5. As stated in Note 3 above, AS 2030.1-1999 also invokes the tests and inspections required by the cylinder standard and/or the manufacturer. Hence compliance with the requirement above also necessitates compliance with the intervals listed in those documents.
6. The physical configuration of the cylinder and its fittings must be as approved by the balloon manufacturer unless any changes are covered by an STC or other approval (ie, CAR 35). Simply replacing a component with another of the same part number may result in configuration changes, because gas component manufacturers may change the design of a component without changing the part number. It is particularly important that any changes to valves, regulators or other fittings on the top of a gas cylinder be carefully monitored. Gas equipment maintenance personnel do not usually have detailed information regarding appropriate fittings for balloon fuel cylinders.
Compliance: For Requirement 1: In accordance with the inspection intervals specified by Australian Standard AS 2030.1-1999.
For Requirement 2: At the expiration of the service life limitation specified by the cylinder specification and/or manufacturer.
This Amendment becomes effective on 19 June 2002.
Background: This AD was initially raised in order to combine the aviation requirements of AD/GAS/1 and State legislative requirements, and also allow for the operational usage of balloon fuel cylinders. Since the initial issue and subsequent amendment, a number of the original assumptions used in those issues were found to have changed.
Amendment 2 addressed those changes, and provided some relief to operators in that the requirement for routine hydrostatic inspection was removed.
Amendment 2 also stipulated a retirement life for cylinders based on certain assumptions regarding operational usage. Information subsequently provided by, and on behalf of, the Australian Ballooning Federation, shows that some of those assumptions were incorrect and that the accumulation of fatigue damage and estimated crack propagation rates, are much less rapid than had been indicated.
Amendment 3 deleted the blanket 25 year retirement life. Requirement 1(b) was also been amended to show that Table 6.1 (defect definitions) is part of AS 2337.1-1999, which is referenced in the inspection standard AS 2030.1-1999. Reference to the “Maintenance Release” was been corrected to “Aircraft Log Book”.
This amendment deletes the “Tare Mass Test” requirement. Advice from Standards Australia indicates that “Tare Mass Testing” of thin walled gas cylinders is not the critical test for corrosion of this type of cylinder.
This amendment also adds the caution at Note 6. A recent accident was caused by a valve assembly which broke during landing, resulting in a fire. The original assembly had been replaced with another which protruded beyond the cylinder safety collar, and as a result was no longer adequately protected.
The requirements and compliance times of this directive are unchanged by this amendment.
Amendment 3 of this Airworthiness Directive became effective on 2 November 2000. Amendment 2 of this Airworthiness Directive became effective on 13 July 2000.
Amendment 1 of this Airworthiness Directive became effective in October 1987.
The original issue of this Airworthiness Directive became effective on 18 April 1986.
David Alan Villiers
Delegate of the Civil Aviation Safety Authority 28 May 2002
The above AD is notified in the Commonwealth of Australia Gazette on 19 June 2002.