AD 2022-15-02 Requires Repetitively Inspecting Certain Stratus Double Burner Hangers

The FAA is adopting a new airworthiness directive (AD) for certain Cameron Balloons Ltd. (Cameron) Stratus double burner assemblies installed on hot air balloons.

This AD was prompted by reports from mandatory continuing airworthiness information (MCAI) originated by an aviation authority of another country to identify and correct an unsafe condition on an aviation product. The MCAI identifies the unsafe condition as fatigue cracking of the weld on Stratus double burner hangers. This AD requires repetitively inspecting certain Stratus double burner hangers and replacing certain Stratus double burners, and prohibits installing certain parts. The FAA is issuing this AD to address the unsafe condition on these products. This AD is effective August 25, 2022.

Supplementary Information: The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 CFR part 39 by adding an AD that would apply to Cameron Stratus double burner assembly part number (P/N) CB8720 and P/N CB8721 installed on hot air balloons. The NPRM published in the Federal Register on May 5, 2022 (87 FR 26699). The NPRM was based on MCAI from the European Union Aviation Safety Agency (EASA), which is the Technical Agent for the Member States of the European Union. EASA issued AD 2021-0042, dated January 29, 2021 (referred to after this as “the MCAI”), to address the unsafe condition on all hot air balloons.

The MCAI states:   An occurrence was been reported of a Stratus burner hanger, [part number] P/N CB8504, failing after landing, leaving one burner unit detached from the load frame. Investigation revealed a limited number of similar failures. Comparable issues have been experienced with other parts of the Stratus product line (see Australian [Civil Aviation Safety Authority] CASA AWB 14-001 [Airworthiness Bulletin AWB 14-001, Issue 3, dated February 5, 2021]). The suspected cause is fatigue cracking of the weld, caused mainly during ground transportation with the burner erect, combined with an overload event. 

This condition, if not detected and corrected, could lead to burner falling on the balloon occupant's head, resulting in injury to balloon occupants. It could also lead to an uncontrolled cold descent and hard landing, possibly resulting in injury to balloon occupants and persons on the ground. 

To address this potential unsafe condition, Cameron Balloons issued the SB [Service Bulletin 28, Revision 3, dated February 3, 2021], providing inspection and replacement instructions. It was determined that some burner hangers cannot be inspected as they are covered with a doubler plate to reinforce the central part of the hanger bracket. 

For the reasons described above, this [EASA] AD requires repetitive detailed inspections (DET) of the affected parts A and, depending on findings, replacement with a serviceable part. This [EASA] AD also requires direct replacement of the burner hanger installed on affected parts B.  

You may examine the MCAI in the AD docket at https://www.regulations.gov under Docket No. FAA-2022-0469. 

In the NPRM, the FAA proposed to require repetitively inspecting certain Stratus double burner hangers and replacing certain other Stratus double burners. The FAA also proposed to prohibit installing certain parts. The FAA is issuing this AD to prevent burners from separating from the balloon. The unsafe condition, if not addressed, could result in an uncontrolled cold descent and hard landing of the balloon.

FMI: www.regulations.gov