[Federal Register Volume 75, Number 186 (Monday, September 27, 2010)]
[Rules and Regulations]
[Pages 59067-59071]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2010-23832]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2009-1100; Directorate Identifier 2009-NE-37-AD;
Amendment 39-16441; AD 2010-20-07]
RIN 2120-AA64
Airworthiness Directives; International Aero Engines AG V2500-A1,
V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5,
V2530-A5, and V2533-A5 Turbofan Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all
International Aero Engines AG (IAE) V2500-A1, V2525-D5 and V2528-D5
turbofan engines and certain serial numbers (S/Ns) of IAE V2522-A5,
V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5
turbofan engines. For certain S/Ns of V2500-A1, V2522-A5, V2524-A5,
V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 series turbofan
engines, this AD requires initial and repetitive on-wing ultrasonic
inspections of the high-pressure compressor (HPC) stage 3 to 8 drum for
cracks. As mandatory terminating action to the repetitive inspections,
this AD requires removal from service of the fully silver plated nuts
attaching the HPC stage 3 to 8 drum to the HPC stage 9 to 12 drum,
removal of silver residue from the HPC stage 3 to 8 drum, and
fluorescent penetrant inspection (FPI) of the stage 3 to 8 drum within
a specified time. For all other engines, this AD requires removal from
service of the fully silver plated nuts attaching the HPC stage 3 to 8
drum to the HPC stage 9 to 12 drum, removal of silver residue from the
HPC stage 3 to 8 drum, and FPI of the HPC stage 3 to 8 drum at the next
drum piece-part exposure. This AD results from reports of 39 HPC stage
3 to 8 drums found cracked since March 2009. We are issuing this AD to
prevent uncontained failure of the HPC stage 3 to 8 drum, which could
result in damage to the airplane.
DATES: This AD becomes effective November 1, 2010. The Director of the
Federal Register approved the incorporation by reference of certain
publications listed in the regulations as of November 1, 2010.
ADDRESSES: You can get the service information identified in this AD
from
[[Page 59068]]
International Aero Engines AG, 400 Main Street, East Hartford, CT
06108; telephone: (860) 565-5515; fax: (860) 565-5510.
The Docket Operations office is located at Docket Management
Facility, U.S. Department of Transportation, 1200 New Jersey Avenue,
SE., West Building Ground Floor, Room W12-140, Washington, DC 20590-
0001.
FOR FURTHER INFORMATION CONTACT: Mark Riley, Aerospace Engineer, Engine
Certification Office, FAA, Engine and Propeller Directorate, 12 New
England Executive Park, Burlington, MA 01803; e-mail:
[email protected]; telephone (781) 238-7758, fax (781) 238-7199.
SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39
with a proposed AD. The proposed AD applies to all IAE V2500-A1, V2525-
D5 and V2528-D5 turbofan engines and certain S/Ns of IAE V2522-A5,
V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5
turbofan engines. We published the proposed AD in the Federal Register
on February 12, 2010 (75 FR 6860). That action proposed to require:
For certain S/Ns of IAE V2500-A1, V2522-A5, V2524-A5,
V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 turbofan
engines:
[cir] Initial and repetitive on-wing ultrasonic inspections of HPC
stage 3 to 8 drums for cracks; and
[cir] As mandatory terminating action to the repetitive ultrasonic
inspections, within 27 months from the effective date of this AD,
removal from service of the fully silver plated nuts attaching the HPC
stage 3 to 8 drum to the HPC stage 9 to 12 drum, removal of silver
residue from the HPC stage 3 to 8 drums, and FPI of the HPC stage 3 to
8 drums.
For all other engines, at the next piece-part exposure of
the HPC stage 3 to 8 drum, removal from service of the fully silver
plated nuts attaching the HPC stage 3 to 8 drum to the HPC stage 9 to
12 drum, removal of silver residue from the HPC stage 3 to 8 drums, and
FPI of the HPC stage 3 to 8 drums.
Examining the AD Docket
You may examine the AD docket on the Internet at http://www.regulations.gov; 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 regulatory evaluation,
any comments received, and other information. The street address for
the Docket Operations office (telephone (800) 647-5527) is provided in
the ADDRESSES section. Comments will be available in the AD docket
shortly after receipt.
Comments
We provided the public the opportunity to participate in the
development of this AD. We have considered the comments received.
Request To Mandate Inspection of Group B and Group C Engines
One commenter, Airbus, requests that we mandate inspection for the
S/N engines identified in Group B and Group C of IAE Service Bulletin
(SB) No. V2500-ENG-72-0594, Revision 5, as these engines may have
operated in a similar environment as the Group A engines.
We do not agree. Engines identified in Groups B and C have not
exhibited cracking similar to that seen in engines listed in Groups A
and D. Therefore, it is not appropriate to mandate inspections on Group
B or C engines at this time. We did not change the AD.
Claim That Root Cause Is Not Yet Determined
Airbus claims that the proposed AD would mandate the inspection
only on engines identified in IAE SB No. V2500-ENG-72-0594 (Groups A
and D) and IAE SB No. V2500-ENG-72-0603 (Group A) without determining
root cause. To properly identify the suspect population, determining
the root cause of the HPC stage 3-8 drum cracking is required.
We do not agree. While we do not yet know the specific root cause
of the contamination causing the corrosion cracking of the HPC stage 3-
8 drum, we do know that engines specified in IAE SB No. V2500-ENG-72-
0594 (Groups A and D) and IAE SB No. V2500-ENG-72-0603 (Group A) may
exhibit HPC stage 3-8 drum corrosion cracking. We did not change the
AD.
Request To Include a Fleetwide Introduction of a Final Fix
Airbus requests that the proposed AD should include a fleet-wide
introduction of the final fix (nuts modification), and in the interim,
the ultrasonic inspection, to correct the cause of HPC stage 3-8 drum
cracking for the entire V2500 fleet.
We partially agree. Paragraph (f)(4)(i) of this AD requires that
all operators of engines requiring these repetitive ultrasonic
inspections remove the fully silver plated nuts, P/N AS44862, or
equivalent, that attach the HPC stage 3 to 8 drum to the HPC stage 9 to
12 drum, within 27 months after the effective date of the AD. Paragraph
(g) of this AD also requires those operators of all other affected
engines to remove the fully silver plated nuts at the next piece-part
exposure of the HPC stage 3-8 drum after the effective date of the AD.
Ultrasonic inspection(s) per IAE SB No. V2500-ENG-72-0594 (Groups A and
D) and IAE SB No. V2500-ENG-72-0603 only affect certain engines and are
not required for the entire fleet. We did not change the AD.
Claim That Proposed AD Is Less Restrictive Than IAE SB
Airbus claims that the proposed AD is less restrictive than the IAE
service bulletins, and it does not recommend immediate action for
V2500-A5 drums above 7,545 cycles-since-new and for V2500-A1 drums
above 10,305 cycles-since-new. It therefore does not meet the criteria
for maximum allowable individual risk per flight.
We do not agree. All ``high cycle'' HPC stage 3 to 8 drums in the
field that required inspections at reduced thresholds, as referenced in
the IAE SBs, have already been inspected. Therefore, an equivalent
level of fleet risk is maintained for the AD action, and meets FAA
criteria. We did not change the AD.
FAA Should Mandate the Nut Removal for the Complete V2500 Fleet
Airbus states that the proposed AD does not put a compliance date
for removal of the fully plated silver nuts for the complete V2500
fleet. Removal of the fully silver plated nuts should be mandated for
the complete V2500 fleet.
We agree that the fully silver plated nuts should be removed from
service for the entire V2500 fleet. However, all engines do not need to
be retrofitted before a specific compliance date. V2500 engines that
have been determined to require repetitive ultrasonic inspections are
at an elevated risk level, and therefore require removal of the fully
silver plated nuts within a specified time period to prevent corrosion
and potential failure of the HPC 3-8 drum. The remaining V2500 engines
that do not require repetitive ultrasonic inspections have been
determined to be at a much lower risk level, and therefore, are only
required to have the fully silver plated nuts removed at the next piece
part exposure. We did not change the AD.
Request To Reference the Latest Service Bulletins
IAE and Japan Airlines request that we reference the latest
revisions of the service bulletins, which are IAE SB No. V2500-ENG-72-
0594, Revision 6, IAE SB No. V2500-ENG-72-0603, Revision 2, and V2500-
ENG-72-0601, Revision 2, as they have been updated to include
additional engine S/Ns and other clarification changes.
We agree. We changed the AD to reference the revised service
bulletins.
[[Page 59069]]
Request To Correct Typos in the Proposed AD
Two commenters request that we change the following:
Paragraph (f)(4) should be revised from ``HPC Stage 8 to 12 drum''
to ``HPC Stage 3 to 8 drum''.
Paragraphs (f)(1), (f)(4)(ii), and (g)(2) should be revised from
``using paragraph 3 of the Accomplishment Instructions of'' to ``using
the paragraph 3 Accomplishment Instructions of''.
We partially agree. We agree that paragraph (f)(4) should be
revised from ``HPC Stage 8 to 12 drum'' to ``HPC Stage 3 to 8 drum,''
We changed the AD.
We also agree that our reference in paragraphs (f)(1), (f)(4)(ii),
and (g)(2) should be revised, but not as recommended. We changed
paragraphs (f)(1), (f)(4)(ii), and (g)(2) from ``using paragraph 3 of
the Accomplishment Instructions of'' to ``use IAE SB No. V2500-ENG-72-
0601, Revision 2, dated April 12, 2010, Accomplishment Instructions,
paragraph 3.''
Material Incorporated by Reference Section Missing From Proposed AD
One commenter states that paragraphs (f)(1), (f)(4)(ii), and (g)(2)
require ultrasonic inspection and cleaning to be performed using the
Accomplishment Instructions of specified revisions of IAE SBs V2500-
ENG-72-0594, V2500-ENG-603, and V2500-ENG-72-0601. These SBs should be
listed in the Material Incorporated by Reference section, which is
missing from the NPRM.
We agree. This Final Rule AD includes the Material Incorporated by
Reference section, which includes those SBs.
Request To Revise the Relevant Service Information
IAE commented to revise the last sentence of the ``Relevant Service
Information'' in the preamble of the AD to change: ``* * * 27 months
from the effective date of the proposed AD'' to ``27 months after the
effective date of this AD''. The commenter states that this could be
interpreted incorrectly as 27 months from February 12, 2010 (date of
the NPRM).
We do not agree that the compliance date could be misinterpreted.
Paragraph (4) of this AD correctly states ``27 months after the
effective date of this AD.'' We did not change the AD.
Request To Revise the Mandatory Terminating Action Compliance Time
IAE requests that we revise the mandatory terminating action
compliance time of ``27 months after the effective date of this AD'' to
a calendar end date of October 31, 2012, to be consistent with the IAE
risk assessment.
We do not agree. Due to the uncertainty of the actual publication
date of the AD, revising the mandatory terminating action from 27
months after the effective date of this AD to a calendar date of
October 31, 2012, may result in a compliance time that is more
restrictive than what was proposed in the NPRM. We did not change the
AD.
Request To Revise the Definition of Piece-Part Exposure
IAE requests that we revise the AD to change paragraph (i) of the
definition of piece-part exposure for the HPC stage 3 to 8 drum from
``removal of the drum from the engine and removal of all blades from
the drum'' to ``separation of the rotating drum hardware from the
static cases and removal of all blades from the HPC stage 3 to 8
drum''. IAE is concerned that confusion could occur with the current
statement.
We do not agree. The current description is accurate. We did not
change the AD.
Request To Eliminate the Mandatory Terminating Action
One commenter requests that we revise paragraph (f)(4) of the AD to
eliminate the 27-month mandatory terminating action requirement to
remove the fully silver plated nuts that attach the HPC stage 3 to 8
drum to the HPC stage 9 to 12 drum. The commenter states that
performing repetitive ultrasonic inspections will provide an acceptable
level of safety, and that incorporation of the 27-month mandatory
terminating action requirement is an unacceptable cost burden to
operators.
We do not agree. We have determined that removal of the fully
silver plated nuts within 27 months from the effective date of the AD
is required to maintain an acceptable level of safety. We did not
change the AD.
Conclusion
We have carefully reviewed the available data, including the
comments received, and determined that air safety and the public
interest require adopting the AD with the changes described previously.
We have determined that these changes will neither increase the
economic burden on any operator nor increase the scope of the AD.
Costs of Compliance
We estimate that this AD will affect 848 IAE V2500-A1, V2522-A5,
V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-A5,
and V2533-A5 turbofan engines installed on airplanes of U.S. registry.
We estimate that 29 of these engines will require ultrasonic
inspections, and that it will take about 3 work-hours per engine to
perform one ultrasonic inspection. We estimate that it will take about
2 work-hours per engine to perform the FPI of the HPC stage 3 to 8
drum, and that the average labor rate is $85 per work-hour. We also
estimate that removal of silver residue from the engine will cost about
$2,600 per engine. Required parts will cost about $795 per engine.
Based on these figures, we estimate the total cost of the AD to U.S.
operators to be $3,030,515.
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 have 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 above, 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); 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.
We prepared a summary of the costs to comply with this AD and
placed it in the AD Docket. You may get a copy of this summary at the
address listed under ADDRESSES.
[[Page 59070]]
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
Adoption of the Amendment
0
Accordingly, under the authority delegated to me by the Administrator,
the Federal Aviation Administration 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:
2010-20-07 International Aero Engines AG: Amendment 39-16441. Docket
No. FAA-2009-1100; Directorate Identifier 2009-NE-37-AD.
Effective Date
(a) This airworthiness directive (AD) becomes effective November
1, 2010.
Affected ADs
(b) None.
Applicability
(c) This AD applies to:
(1) All International Aero Engines AG (IAE) V2500-A1 turbofan
engines; and
(2) All IAE V2525-D5 and V2528-D5 turbofan engines; and
(3) IAE V2522-A5, V2524-A5, V2527-A5, V2527E-A5, V2527M-A5,
V2530-A5, and V2533-A5 turbofan engines with serial numbers (S/Ns)
up to and including V13181, and with S/Ns from V15000 up to and
including V15245.
(4) These engines are installed on, but not limited to, Airbus
A319, A320, and A321, and McDonnell Douglas MD-90 airplanes.
Unsafe Condition
(d) This AD results from reports of 39 high-pressure compressor
(HPC) stage 3 to 8 drums found cracked since March 2009. We are
issuing this AD to prevent uncontained failure of the HPC stage 3 to
8 drum, which could result in damage to the airplane.
Compliance
(e) You are responsible for having the actions required by this
AD performed within the compliance times specified unless the
actions have already been done.
Engines Requiring Ultrasonic Inspections of the HPC Stage 3 to 8 Drum
(f) For IAE V2522-A5, V2524-A5, V2527-A5, V2527E-A5, V2527M-A5,
V2530-A5, and V2533-A5 turbofan engines with S/Ns in ``Group A'' or
``Group D'' in IAE Service Bulletin (SB) No. V2500-ENG-72-0594,
Revision 6, dated April 12, 2010, and for V2500-A1 turbofan engines
with S/Ns in ``Group A'' in IAE SB No. V2500-ENG-72-0603, Revision
2, dated March 17, 2010, do the following:
(1) Perform an initial ultrasonic inspection of the HPC stage 3
to 8 drum using IAE SB No. V2500-ENG-72-0594, Revision 6, dated
April 12, 2010, Accomplishment Instructions, paragraph 3, or IAE SB
No. V2500-ENG-72-0603, Revision 2, dated March 17, 2010,
Accomplishment Instructions, paragraph 3, before accumulating 5,200
cycles-since-new (CSN) or within 500 cycles from the effective date
of this AD, whichever occurs later.
(2) Thereafter, perform repetitive ultrasonic inspections of the
HPC stage 3 to 8 drum for cracks within every 500 cycles-since-last-
inspection.
(3) If cracks or crack indications are identified, remove the
drum from service before further flight.
Mandatory Terminating Action
(4) As mandatory terminating action to the repetitive
inspections required by this AD, at the next engine shop visit, but
no later than 27 months after the effective date of this AD, do the
following before returning any HPC stage 3 to 8 drum to service:
(i) Remove from service fully silver plated nuts, part number
(P/N) AS44862 or equivalent, that attach the HPC stage 3 to 8 drum
to the HPC stage 9 to 12 drum.
(ii) Remove the silver residue from the HPC stage 3 to 8 drum
using the IAE SB No. V2500-ENG-72-0601, Revision 2, dated April 12,
2010, Accomplishment Instructions, paragraph 3. Drums cleaned before
the effective date of this AD using engine manual task 72-41-11-110-
001 satisfy this requirement.
(iii) Fluorescent penetrant inspect (FPI) the HPC stage 3 to 8
drum for cracks, and remove from service any drum found cracked. You
can find guidance on performing an FPI of the HPC stage 3 to 8 drum
in IAE engine manual task 72-41-11-200-001.
(iv) Installation of a zero-time HPC stage 3 to 8 drum or a drum
that has never operated with fully silver plated nuts, P/N AS44862
or equivalent, that attach the HPC stage 3 to 8 drum to the HPC
stage 9 to 12 drum eliminates the need for the cleaning and FPI
required by paragraphs (f)(4)(ii) and (f)(4)(iii) of this AD.
All Other Engines
(g) For all other engines, at the next piece-part exposure of
the HPC stage 3 to 8 drum after the effective date of this AD, do
the following before returning the drum to service:
(1) Remove from service fully silver plated nuts, P/N AS44862 or
equivalent, that attach the HPC stage 3 to 8 drum to the HPC stage 9
to 12 drum.
(2) Remove the silver residue from the HPC stage 3 to 8 drum
using IAE SB No. V2500-ENG-72-0601, Revision 2, dated April 12,
2010, Accomplishment Instructions, paragraph 3. Drums cleaned before
the effective date of this AD using engine manual task 72-41-11-110-
001 satisfy this requirement.
(3) FPI the HPC stage 3 to 8 drum for cracks, and remove from
service any drum found cracked. You can find guidance on performing
an FPI of the HPC stage 3 to 8 drum in IAE engine manual task 72-41-
11-200-001.
(4) Installation of a zero-time HPC stage 3 to 8 drum or a drum
that has never operated with fully silver plated nuts, P/N AS44862
or equivalent, that attach the HPC stage 3 to 8 drum to the HPC
stage 9 to 12 drum eliminates the need for the cleaning and FPI
required by paragraphs (g)(2) and (g)(3) of this AD.
Definitions
(h) For the purpose of this AD, an engine shop visit is the
induction of an engine into the shop for maintenance involving the
separation of a pair of major mating engine flanges, except that the
separation of engine flanges solely for the purposes of
transportation without subsequent engine maintenance is not an
engine shop visit.
(i) For the purpose of this AD, piece-part exposure is removal
of the HPC stage 3 to 8 drum from the engine and removal of all
blades from the drum.
Previous Credit
(j) Initial or repetitive ultrasonic inspections of the HPC
stage 3 to 8 drum using IAE SB No. V2500-ENG-72-0594, Revision 3,
dated August 7, 2009, or Revision 4, dated October 13, 2009, or
Revision 5, dated November 23, 2009, before the effective date of
this AD, meets the inspection requirements of paragraphs (f)(1)
through (f)(3) of this AD.
(k) Initial or repetitive ultrasonic inspections of the HPC
stage 3 to 8 drum using IAE SB No. V2500-ENG-72-0603, Original
Issue, dated November 24 2009, or Revision 1, dated December 18,
2009, before the effective date of this AD, meets the inspection
requirements of paragraphs (f)(1) through (f)(3) of this AD.
Alternative Methods of Compliance (AMOCS)
(l) The Manager, Engine Certification Office, has the authority
to approve AMOCs for this AD if requested using the procedures found
in 14 CFR 39.19.
Related Information
(m) Contact Mark Riley, Aerospace Engineer, Engine Certification
Office, FAA, Engine and Propeller Directorate, 12 New England
Executive Park, Burlington, MA 01803; e-mail: [email protected];
telephone (781) 238-7758, fax (781) 238-7199, for more information
about this AD.
(n) Contact International Aero Engines AG, 400 Main Street, East
Hartford, CT 06108; telephone: (860) 565-5515; fax: (860) 565-5510,
for a copy of the service information referenced in this AD.
Material Incorporated by Reference
(o) You must use the service information specified in the
following Table 1 to perform the inspections and silver residue
removal required by this AD. The Director of the Federal Register
approved the incorporation by reference of the documents listed in
the following Table 1 in accordance with 5 U.S.C. 552(a) and 1 CFR
part 51. Contact International Aero Engines AG, 400 Main Street,
East Hartford, CT 06108; telephone:
[[Page 59071]]
(860) 565-5515; fax: (860) 565-5510, for a copy of this service
information. You may review copies at the FAA, New England Region,
12 New England Executive Park, Burlington, MA; or at the National
Archives and Records Administration (NARA). For information on the
availability of this material at NARA, call (202) 741-6030, or go
to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.
Table 1--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
International Aero Engines Service
Bulletin No. Page Revision Date
----------------------------------------------------------------------------------------------------------------
V2500-ENG-72-0594...................... ALL.................. 6 April 12, 2010.
Total Pages: 61....................
V2500-ENG-72-0601...................... ALL.................. 2 April 12, 2010.
Total Pages: 9.....................
V2500-ENG-72-0603...................... ALL.................. 2 March 17, 2010.
Total pages: 46....................
----------------------------------------------------------------------------------------------------------------
Issued in Burlington, Massachusetts, on September 15, 2010.
Robert J. Ganley,
Acting Manager, Engine and Propeller Directorate, Aircraft
Certification Service.
[FR Doc. 2010-23832 Filed 9-24-10; 8:45 am]
BILLING CODE 4910-13-P