Document ID: FAA-2021-0874-0003
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Rolls-Royce Corp. (Type Certificate Previously Held by Allison Engine Co.) Turboprop Engines
Posted Date: 2021-12-28T05:00Z

[Federal Register Volume 86, Number 246 (Tuesday, December 28, 2021)]
[Rules and Regulations]
[Pages 73658-73660]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2021-28136]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2021-0874; Project Identifier AD-2021-00668-E; 
Amendment 39-21892; AD 2022-01-04]
RIN 2120-AA64

Airworthiness Directives; Rolls-Royce Corporation (Type 
Certificate Previously Held by Allison Engine Company) Turboprop 
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 
certain Rolls-Royce Corporation (RRC) AE 2100D3 model turboprop 
engines. This AD was prompted by an in-flight shutdown (IFSD) of an 
engine and subsequent investigation by the manufacturer that revealed a 
crack in the 3rd-stage compressor wheel. This AD requires replacement 
of the affected 3rd-stage compressor wheel. The FAA is issuing this AD 
to address the unsafe condition on these products.

DATES: This AD is effective February 2, 2022.

ADDRESSES: For service information identified in this final rule, 
contact Rolls-Royce Corporation, Rolls-Royce Meridian Center, 450 South 
Meridian Street, Indianapolis, IN 46225-1103; phone: (317) 230-1200; 
email: Royce.com">[email protected]Royce.com. You may view this service 
information at the FAA, Airworthiness Products Section, Operational 
Safety Branch, 1200 District Avenue, Burlington, MA 01803. For 
information on the availability of this material at the FAA, call (817) 
222-5110. It is also available at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2021-0874.

[[Page 73659]]

Examining the AD Docket

    You may examine the AD docket at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2021-0874; 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 final rule, any 
comments received, and other information. The 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: Kyri Zaroyiannis, Aviation Safety 
Engineer, Chicago ACO, FAA, 2300 E. Devon Avenue, Des Plaines, IL 
60018; phone: (847) 294-7836; fax: (847) 294-7834; email: 
[email protected].

SUPPLEMENTARY INFORMATION:

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to certain RRC AE 2100D3 
model turboprop engines. The NPRM published in the Federal Register on 
October 12, 2021 (86 FR 56660). The NPRM was prompted by an uncommanded 
IFSD of a RRC AE 3007A1 model turbofan engine installed on an Embraer 
S.A. model EMB-145 airplane (marketed as ERJ-145), while conducting a 
revenue flight. The manufacturer's investigation of this incident 
revealed that the IFSD resulted from a low-cycle fatigue crack in the 
dovetail slot for the blade attachment in the 3rd-stage compressor 
wheel, causing one 3rd-stage compressor blade to release. The crack 
initiated in the dovetail slot due to a sharp corner in the wheel slot 
geometry. The broaching process was identified as the cause of the 
crack and parts from this manufacturing lot required removal from 
service.
    In response to this event and the manufacturer's subsequent 
investigation, the FAA issued a final rule; request for comments, AD 
2020-16-13 (85 FR 45769, July 30, 2020), requiring replacement of 
certain 3rd-stage compressor wheels installed on RRC AE 3007A, AE 
3007A1, AE 3007A1/1, AE 3007A1/2, AE 3007A1/3, AE 3007A1E, AE 3007A1P, 
and AE 3007A3 model turbofan engines before the 3rd-stage compressor 
wheels accumulate a specified number of cycles. The actions required by 
AD 2020-16-13 address engines that experienced high stresses at the 
3rd-stage compressor wheel location and accumulated cycles at a high 
rate. In the NPRM, the FAA proposed to require replacement of certain 
AE 2100D3 3rd-stage compressor wheels that were produced in the same 
lot as the AE 3007 3rd-stage compressor wheels identified in AD 2020-
16-13, before they accumulate a specified number of cycles. The FAA is 
issuing this AD to address the unsafe condition on these products.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from one anonymous commenter. The 
anonymous commenter supported the NPRM without change.

Conclusion

    The FAA reviewed the relevant data, considered the comment 
received, and determined that air safety requires adopting the AD as 
proposed. Accordingly, the FAA is issuing this AD to address the unsafe 
condition on these products. Except for a minor editorial change to the 
contact address for service information, this AD is adopted as proposed 
in the NPRM.

Related Service Information

    The FAA reviewed Rolls-Royce Alert Service Bulletin (ASB) AE 
2100D3-A-72-330, Engine--3rd Stage Compressor Wheel Removal for Reduced 
Life Limit, dated June 11, 2021. The ASB describes procedures for 
removal of a certain 3rd-stage compressor wheel.

Costs of Compliance

    The FAA estimates that this AD affects 15 engines installed on 
airplanes of U.S. registry.
    The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Remove and replace 3rd-stage            125 work-hours x $85 per         $32,844         $43,469        $652,035
 compressor wheel.                       hour = $10,625.
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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 products 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.

The Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 14 CFR part 39 as follows:

[[Page 73660]]

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:

2022-01-04 Rolls-Royce Corporation (Type Certificate previously held 
by Allison Engine Company): Amendment 39-21892; Docket No. FAA-2021-
0874; Project Identifier AD-2021-00668-E.

(a) Effective Date

    This airworthiness directive (AD) is effective February 2, 2022.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to Rolls-Royce Corporation (RRC) AE 2100D3 model 
turboprop engines with a 3rd-stage compressor wheel, part number (P/
N) 23084158, and with a serial number listed in Figure 1 to 
paragraph (c) of this AD.

Figure 1 to Paragraph (c)--Serial Numbers of Affected P/N 23084158 3rd-
stage Compressor Wheels

L343502
L343539
L343545
L343546
L343547
L343550
L343553
L343554
L343555
L343566
L343569
L343573
L343576
L343578
L343579
L343580
L343584
L343588
L343593
L343594
L343597
L343602

(d) Subject

    Joint Aircraft System Component (JASC) Code 7230, Turbine Engine 
Compressor Section.

(e) Unsafe Condition

    This AD was prompted by an in-flight shutdown of an engine 
during a revenue flight and subsequent investigation by the 
manufacturer that revealed a crack in the 3rd-stage compressor 
wheel. The FAA is issuing this AD to prevent failure of the 3rd-
stage compressor wheel. The unsafe condition, if not addressed, 
could result in an uncontained release of the 3rd-stage compressor 
wheel, damage to the engine, and damage to the airplane.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Required Actions

    Before the affected 3rd-stage compressor wheel exceeds 5,200 
flight cycles since new, remove the affected 3rd-stage compressor 
wheel and replace with a part eligible for installation.

(h) Definition

    For the purpose of this AD, a part eligible for installation is 
a 3rd-stage compressor wheel that does not have a P/N and a serial 
number listed in the Applicability, paragraph (c) of this AD.

(i) Special Flight Permit

    A special flight permit may be issued in accordance with 14 CFR 
21.197 and 21.199 to permit a one-time, non-revenue ferry flight to 
a location where the engine can be removed from service. This ferry 
flight must be performed with only essential flight crew.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Chicago ACO, FAA, has the authority to approve 
AMOCs for this AD, if requested using the procedures found in 14 CFR 
39.19. In accordance with 14 CFR 39.19, send your request to your 
principal inspector or local Flight Standards District Office, as 
appropriate. If sending information directly to the manager of the 
certification office, send it to the attention of the person 
identified in paragraph (k) of this AD.
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.

(k) Related Information

    For more information about this AD, contact Kyri Zaroyiannis, 
Aviation Safety Engineer, Chicago ACO, FAA, 2300 E. Devon Avenue, 
Des Plaines, IL 60018; phone: (847) 294-7836; fax: (847) 294-7834; 
email: [email protected].

(l) Material Incorporated by Reference

    None.

    Issued on December 21, 2021.
Lance T. Gant, Director,
Compliance & Airworthiness Division, Aircraft Certification Service.
[FR Doc. 2021-28136 Filed 12-27-21; 8:45 am]
BILLING CODE 4910-13-P