Document ID: FAA-2009-0811-0010
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Rolls-Royce Corporation Turbofan Engines
Posted Date: 2013-08-08T04:00Z

[Federal Register Volume 78, Number 153 (Thursday, August 8, 2013)]
[Proposed Rules]
[Pages 48339-48341]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2013-19162]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0811; Directorate Identifier 2008-NE-41-AD]
RIN 2120-AA64

Airworthiness Directives; Rolls-Royce Corporation Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to supersede an existing airworthiness directive 
(AD)

[[Page 48340]]

that applies to certain Rolls-Royce Corporation (RRC) AE 3007A series 
turbofan engines. The existing AD currently requires removing certain 
high-pressure turbine (HPT) stage 2 wheels, or performing inspections 
on them, and reduces their approved life limits. This proposed AD would 
clarify the AE 3007A turbofan engine model applicability, would further 
reduce the approved life limits of affected HPT stage 2 wheels, and 
would eliminate the inspections required by the existing AD. We are 
proposing this AD to prevent uncontained failure of the HPT stage 2 
wheel, damage to the engine, and damage to the airplane.

DATES: We must receive comments on this proposed AD by October 7, 2013.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Rolls-Royce Corporation, 450 South Meridian Street, Mail Code NB-01-06, 
Indianapolis, IN 46225, phone: 317-230-1667; email: royce.com">CMSEindyOSD@rolls-royce.com; Internet: www.rolls-royce.com. You may view this service 
information at the FAA, Engine & Propeller Directorate, 12 New England 
Executive Park, Burlington, MA. For information on the availability of 
this material at the FAA, call 781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Management Facility 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this proposed AD, the regulatory 
evaluation, any comments received, and other information. The street 
address for the Docket Office (phone: 800-647-5527) is in the ADDRESSES 
section. Comments will be available in the AD docket shortly after 
receipt.

FOR FURTHER INFORMATION CONTACT: Kyri Zaroyiannis, Aerospace Engineer, 
Chicago Aircraft Certification Office, Small Airplane Directorate, FAA, 
2300 E. Devon Ave., Des Plaines, IL 60018; phone: 847-294-7836; fax: 
847-294-7834; email: kyri.zaroyiannis@faa.gov.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposed AD. Send your comments to an address 
listed under the ADDRESSES section. Include ``Docket No. FAA-2009-0811; 
Directorate Identifier 2008-NE-41-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this proposed AD. We 
will consider all comments received by the closing date and may amend 
this proposed AD because of those comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact we 
receive about this proposed AD.

Discussion

    On September 1, 2010, we issued AD 2010-19-01, Amendment 39-16429 
(75 FR 57660, September 22, 2010), for RRC AE 3007A series turbofan 
engines with an HPT stage 2 wheel, part number (P/N) 23069438, 
23069592, 23074462, 23074644, 23075345, or 23084520, installed. AD 
2010-19-01 requires removing certain HPT stage 2 wheels, or performing 
repetitive eddy current inspections (ECIs) or surface wave ultrasonic 
test (SWUT) inspections on them for cracks. AD 2010-19-01 also reduces 
the approved life limits of certain HPT stage 2 wheels. AD 2010-19-01 
resulted from reports of cracked HPT stage 2 wheels. We issued AD 2010-
19-01 to prevent uncontained failure of the HPT stage 2 wheel, damage 
to the engine, and damage to the airplane.

Actions Since Existing AD Was Issued

    Since we issued AD 2010-19-01 (75 FR 57660, September 22, 2010), 
RRC did additional analysis and concluded that lower life limits for 
the affected HPT stage 2 wheels are necessary. RRC based their results 
on inspection data collected under AD 2010-19-01. In addition, we 
determined that it is appropriate to establish the new lower life limit 
to remove the parts from service, and to eliminate the inspection 
requirements that were needed to provide additional data in support of 
the analysis for the reduced life limits. We also changed the 
applicability from RRC AE 3007A series turbofan engines to AE 3007A, 
A1, A1/1, A1/2, A1/3, A1P, A1E, and A3 turbofan engines, for added 
clarity. The AE 3007A2 turbofan engine is not included in the 
applicability because affected HPT stage 2 wheels are not installed on 
that engine.

Relevant Service Information

    We reviewed RRC Alert Service Bulletin (ASB) No. AE 3007A-A-72-414, 
Revision 1, dated December 5, 2012. The ASB lists the lower approved 
life limits of the affected HPT stage 2 wheels.

FAA's Determination

    We are proposing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in RRC AE 3007A, A1, A1/1, A1/2, A1/3, A1P, 
A1E, and A3 turbofan engines with affected HPT stage 2 wheels, 
installed.

Proposed AD Requirements

    This proposed AD would clarify the AE 3007A turbofan engine model 
applicability from stating AE 3007A series turbofan engines, to stating 
AE 3007A, A1, A1/1, A1/2, A1/3, A1P, A1E, and A3 turbofan engines. This 
proposed AD would also further reduce the approved life limits of 
affected HPT stage 2 wheels, and would eliminate the initial and 
repetitive ECIs and SWUT inspections on HPT stage 2 wheels for cracks 
as required by the existing AD 2010-19-01 (75 FR 57660, September 22, 
2010).

Costs of Compliance

    We estimate that this proposed AD would affect 18 engines installed 
on airplanes of U.S. registry. We also estimate that a replacement HPT 
stage 2 wheel would cost about $145,524, and that it would be replaced 
during engine shop visit at no additional labor cost. Based on these 
figures, we estimate the total cost of the AD to U.S. operators to be 
$2,619,432.

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

[[Page 48341]]

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 proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would 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 the proposed 
regulation:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979),
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction, and
    (4) 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 Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 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 removing airworthiness directive (AD) 
2010-19-01, Amendment 39-16429 (75 FR 57660, September 22, 2010), and 
adding the following new AD:

Roll-Royce Corporation (Formerly Allison Engine Company): Docket No. 
FAA-2009-0811; Directorate Identifier 2008-NE-41-AD.

(a) Comments Due Date

    The FAA must receive comments on this AD action by October 7, 
2013.

(b) Affected ADs

    This AD supersedes AD 2010-19-01, Amendment 39-16429 (75 FR 
57660, September 22, 2010).

(c) Applicability

    This AD applies to the following Rolls-Royce Corporation (RRC) 
AE 3007A, A1, A1/1, A1/2, A1/3, A1P, A1E, and A3 turbofan engines:
    (1) With an installed high-pressure turbine (HPT) stage 2 wheel, 
part number (P/N) 23084520, or
    (2) With an installed HPT stage 2 wheel, P/N 23069438, 23069592, 
23074462, 23074644, or 23075345, except for the HPT stage 2 wheel 
serial numbers listed in Table 2 through Table 5 of RRC Alert 
Service Bulletin (ASB) No. AE 3007A-A-72-414, Revision 1, dated 
December 5, 2012. Those HPT stage 2 wheels maintain their existing 
approved life limits.

(d) Unsafe Condition

    This AD was prompted by stress and lifing analysis resulting in 
lower approved life limits for certain HPT stage 2 wheels. We are 
issuing this AD to prevent uncontained failure of the HPT stage 2 
wheel, damage to the engine, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) For HPT stage 2 wheels, P/N 23069438 and P/N 23069592, do 
the following:
    (i) For HPT stage 2 wheels that have 9,500 cycles since new 
(CSN) or more on the effective date of this AD, remove the HPT stage 
2 wheel from service within 15 cycles-in-service (CIS) after the 
effective date of this AD.
    (ii) After the effective date of this AD, do not approve for 
return to service any engine with an HPT stage 2 wheel, P/N 23069438 
or P/N 23069592, that exceeds the new life limit of 9,500 CSN.
    (2) For HPT stage 2 wheels, P/N 23074462, do the following:
    (i) For AE 3007A1E turbofan engines with HPT stage 2 wheels 
installed that have 7,500 CSN or more on the effective date of this 
AD, and for the AE 3007A, A1, A1/1, A1/2, A1/3, A1P, and A3 turbofan 
engines with HPT stage 2 wheels installed that have 9,500 CSN or 
more on the effective date of this AD, remove the wheel from service 
within 15 CIS after the effective date of this AD.
    (ii) Thereafter:
    (A) Do not approve for return to service any AE 3007A1E turbofan 
engine with an HPT stage 2 wheel, P/N 23074462, installed, that 
exceeds the new life limit of 7,500 CSN; and
    (B) Do not approve for return to service any AE 3007A, A1, A1/1, 
A1/2, A1/3, A1P, and A3 turbofan engines with an HPT stage 2 wheel, 
P/N 23074462, installed, that exceeds the new life limit of 9,500 
CSN.
    (C) Throughout the life of the HPT stage 2 wheel, always use the 
lowest life limit applicable to any engine model in which the part 
was used in service. If life usage records are not sufficient to 
identify all engine models in which the part has been flown, the 
lowest life applicable to any engine model for which the part is 
eligible must be used.
    (3) For HPT stage 2 wheels, P/N 23074644 and P/N 23075345, do 
the following:
    (i) For HPT stage 2 wheels that have 9,500 CSN or more on the 
effective date of this AD, remove the HPT stage 2 wheel from service 
within 15 CIS after the effective date of this AD.
    (ii) Thereafter, do not approve for return to service any engine 
with an HPT stage 2 wheel, P/N 23074644 or P/N 23075345, installed, 
that exceeds the new life limit of 9,500 CSN.
    (4) For HPT stage 2 wheels, P/N 23084520, do the following:
    (i) For HPT stage 2 wheels that have 23,000 CSN or more on the 
effective date of this AD, remove the HPT stage 2 wheel from service 
before the next flight after the effective date of this AD.
    (ii) Thereafter, do not approve for return to service any engine 
with an HPT stage 2 wheel, P/N 23084520, installed, that exceeds the 
new life limit of 23,000 CSN.

(f) Alternative Methods of Compliance

    The Manager, Chicago Aircraft Certification Office, may approve 
alternative methods of compliance for this AD. Use the procedures 14 
CFR 39.19 to make your request.

(g) Related Information

    (1) For more information about this AD, contact Kyri 
Zaroyiannis, Aerospace Engineer, Chicago Aircraft Certification 
Office, Small Airplane Directorate, FAA, 2300 E. Devon Ave., Des 
Plaines, IL 60018; phone: 847-294-7836; fax: 847-294-7834; email: 
kyri.zaroyiannis@faa.gov.
    (2) Refer to RRC ASB No. AE 3007A-A-72-414, Revision 1, dated 
December 5, 2012, for related information.
    (3) For service information identified in this AD, contact 
Rolls-Royce Corporation, 450 South Meridian Street, Mail Code NB-01-
06, Indianapolis, IN 46225, phone: 317-230-1667; email: 
royce.com">CMSEindyOSD@rolls-royce.com; Internet: www.rolls-royce.com.
    (4) You may view this service information at the FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, 
MA. For information on the availability of this material at the FAA, 
call 781-238-7125.

    Issued in Burlington, Massachusetts, on August 1, 2013.
Robert J. Ganley,
Acting Assistant Directorate Manager, Engine & Propeller Directorate, 
Aircraft Certification Service.
[FR Doc. 2013-19162 Filed 8-7-13; 8:45 am]
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