COMMONWEALTH OF AUSTRALIA (Civil Aviation Regulations 1998), PART 39 - 105 CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES
Robinson R22 Series Helicopters
AD/R22/41
Amdt 1
Upper Steel Tube Frames - 2 2/96 DM
Applicability: All model R22 helicopters with P/N A020-2 steel tube frames serial numbers 0400 and higher installed.
Note: The A020-2 frames below serial number 0400 are subject to inspection according to AD/R22/12 Amdt 2.
Requirement: Remove the centre rear cowling skin, P/N A032-3, above the upper steel tube frame, P/N A020-2. With the aid of a torch and a large mirror (greater than 50 mm diameter) visually inspect all welds and tubing of the A020-2 frame for cracks or corrosion.
Pay particular attention to areas indicated in the figure below (from figure 2-10 of the Robinson R22 Maintenance Manual). Replace the centre rear cowling skin, P/N A032-3, at the completion of the inspection.
COMMONWEALTH OF AUSTRALIA (Civil Aviation Regulations 1998), PART 39 - 105 CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES
Compliance: 1. a. For aircraft used in aerial work operations: Inspect before 25 hours time in service after 20 December 1995. Re-inspect at intervals not to exceed 25 hours time in service.
The initial inspection must be done by a licensed aircraft maintenance engineer. Subsequent inspections may be performed by the pilot in command except where the aircraft is undergoing an inspection for maintenance release. A copy of this Directive must be carried in the aircraft and the required inspections marked on the maintenance release.
An aerial work aircraft is to include any aircraft with an unknown history of operation since new or since overhaul of the A020-2 frame. Aircraft which have been used for aerial work for any period of time since new or since the last overhaul of the A020-2 frame are also to be classed as aerial work aircraft.
1. b. For all other aircraft operations: Inspect before 100 hours time in service after 20 December 1995. Re-inspect at intervals not to exceed 100 hours time in service.
Background: Fatigue cracks were found on early A020-2 frames in areas that may not have been included in regular maintenance. These areas have now been included in the normal 100 hourly inspection. The early frames have special inspection instructions in the Robinson R22 Maintenance Manual and are covered by AD/R22/12 Amdt 2. All frames also have a retirement life in the Maintenance Manual which is mandatory.
The Authority received reports that indicated later A020-2 frames were also failing before reaching the retirement life. This Directive was raised to highlight the directed visual inspection in the Maintenance Manual for later A020-2 frames.
Since issue of this Directive several more frames have been found cracked and two reports of frames failing in flight have been received. Most failures occurred on aircraft used in mustering roles in which the fatigue loads on the frame may be more severe. This reduces the fatigue life and requires more stringent inspections.
This Amendment reduces the visual inspection interval for aircraft engaging in aerial work. An immediate inspection is recommended if any unusual vibration is felt when the aircraft is in flight.
The inspection intervals may be extended if the frame is strengthened appropriately. Any such scheme must be approved through a CASA District Office and by the manufacturer before being incorporated in the aircraft.
Overview
The Civil Aviation Safety Authority (CASA) introduced the Civil Aviation Regulations 1998, specifically Part 39 - 105, to address safety concerns related to the upper steel tube frames of Robinson R22 series helicopters. Enacted by the Commonwealth of Australia, the policy objective of these regulations is to ensure the airworthiness of aircraft by mandating regular inspections and maintenance checks. This particular amendment, AD/R22/41 Amdt 1, was developed in response to reports of fatigue cracks and failures in the upper steel tube frames of certain R22 helicopters, particularly those used in aerial work operations where the fatigue loads may be more severe. The regulation requires detailed visual inspections of the welds and tubing of the A020-2 frame for cracks or corrosion, with specific intervals and conditions for inspection based on the type of operation the helicopter is involved in. Ensuring compliance with these directives helps maintain the safety and reliability of these aircraft in various operational environments.
Scope and Application
The Civil Aviation Regulations 1998, specifically PART 39 - 105, outlines airworthiness directives issued by the Civil Aviation Safety Authority (CASA) for the Robinson R22 series helicopters. AD/R22/41 Amendment 1 applies to all model R22 helicopters with specific upper steel tube frames (serial numbers 0400 and higher). The directive mandates a visual inspection for cracks or corrosion on the welds and tubing of the A020-2 frames, with a particular focus on areas indicated in the Robinson R22 Maintenance Manual. The initial inspection must be conducted by a licensed aircraft maintenance engineer, while subsequent inspections can be performed by the pilot in command, except where the aircraft is undergoing a maintenance release inspection. The directive applies nationally across Australia, with compliance monitored by CASA. The inspection intervals vary depending on the operational context of the aircraft, with aerial work operations requiring inspections at intervals not exceeding 25 hours, while other operations must adhere to a maximum interval of 100 hours. This directive aims to enhance safety by ensuring the structural integrity of the specified helicopter frames, addressing instances of premature failure reported in the field.
Key Provisions
The Civil Aviation Regulations 1998, as amended, include specific provisions under Part 39 - 105 concerning the airworthiness directives for the Robinson R22 series helicopters. Specifically, AD/R22/41 Amendment 1 mandates that for helicopters with model R22 with P/N A020-2 steel tube frames serial numbers 0400 and higher, the centre rear cowling skin must be removed, and all welds and tubing must be visually inspected for cracks or corrosion (AD/R22/41). This inspection should be done using a torch and a large mirror (greater than 50 mm in diameter) to ensure visibility and accuracy. Once the inspection is completed, the centre rear cowling skin must be replaced. This directive applies to all model R22 helicopters with the specified serial numbers.
The obligations imposed by these regulations are clear. For aircraft used in aerial work operations, the initial inspection must be conducted by a licensed aircraft maintenance engineer, while subsequent inspections can be carried out by the pilot in command, except where the aircraft is undergoing maintenance release. For all other aircraft operations, the initial inspection must occur before 100 hours of time in service after 20 December 1995, with re-inspections at intervals not exceeding 100 hours (AD/R22/41). These inspections are crucial to ensure the safety and airworthiness of the aircraft and must be documented accordingly.
Breaching these regulations can result in serious consequences. Non-compliance with airworthiness directives can lead to safety hazards and potential accidents, which can have dire implications for both the operators and the general public. Civil Aviation Safety Authority (CASA) can impose penalties for non-compliance, which can include fines or other legal actions. The specific penalties are outlined in the Civil Aviation Act 1988, which governs aviation safety and can include substantial financial penalties, suspension or revocation of airworthiness certificates, and criminal charges in severe cases. It is therefore imperative that all operators adhere strictly to the directives to avoid any legal repercussions.