Document ID: FAA-2007-26966-0016
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Rolls-Royce Corporation AE 3007A and AE 3007C Series Turbofan Engines
Posted Date: 2007-11-28T05:00Z

[Federal Register: November 28, 2007 (Volume 72, Number 228)]
[Rules and Regulations]               
[Page 67242-67245]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr28no07-6]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-26966; Directorate Identifier 99-NE-01-AD; 
Amendment 39-15271; AD 2007-24-05]
RIN 2120-AA64

 
Airworthiness Directives; Rolls-Royce Corporation AE 3007A and AE 
3007C Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

-----------------------------------------------------------------------

SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for Rolls-Royce Corporation (RRC) AE 3007A and AE 3007C series 
turbofan engines. That AD currently prohibits any flight following a 
ground engine start where the engine oil temperature is below 32 [deg]F 
(0 [deg]C), unless certain preflight operational procedures are 
followed. This AD also requires those actions and would also require a 
terminating action. This AD results from design improvements to 
components in the accessory gearbox air turbine starter mounting pad. 
We are issuing this AD to prevent an in-flight engine shutdown due to 
loss of engine oil from the engine accessory gearbox starter pad shaft 
seal drain and possible loss of the airplane.

DATES: This AD becomes effective January 2, 2008. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of January 2, 2008.

ADDRESSES: You can get the service information identified in this AD 
from Rolls-Royce Corporation, P.O. Box 420, Indianapolis, IN 46206; 
telephone (317) 230-3774; fax (317) 230-8084; e-mail: 
indy.pubs.services@rolls-royce.com.
    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: Kyri Zaroyiannis, Aerospace Engineer, 
Chicago Aircraft Certification Office, Small Airplane Directorate, FAA, 
2300 E. Devon Ave., Des Plaines, IL 60018; telephone (847) 294-7836; 
fax (847) 294-7834.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 by 
superseding AD 99-02-51, Amendment 39-11108 (64 FR 16339, April 5, 
1999), with a proposed AD. The proposed AD applies to RRC AE 3007A and 
AE 3007C series turbofan engines. We published the proposed AD in the 
Federal Register on March 29, 2007 (72 FR 14724). That action proposed 
to:
     Prohibit before further flight, any flight following a 
ground engine start where the engine oil temperature is below 32 [deg]F 
(0 [deg]C), unless certain preflight operational procedures are 
followed to ensure that there is no excessive loss of oil from leakage 
at the air turbine starter shaft; and
     Require terminating action to the prohibition requirements 
of the existing AD, by removing from service certain seal P/Ns from the 
accessory gearbox air turbine starter mounting pad and installing an 
improved seal; and
     Require removing certain P/N drain caps, drain adapters, 
and orifice inserts, and installing an open adapter on the starter pad 
drain.

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

[[Page 67243]]

development of this AD. We have considered the comments received.

Request To Continue To Allow Existing Approved AMOCs

    Four commenters, ExpressJet Inc., RRC, Embraer, and Cessna Aircraft 
Company state that alternative methods of compliance (AMOCs) currently 
approved for AD 99-02-51 should be allowed while this AD is not 
incorporated or until September 30, 2009. Paragraph (l) of the proposed 
rule states that AMOCs approved for AD 99-02-51 are not approved for 
the new rule. Until all engines are modified as required by paragraph 
(g) of the proposed rule, an aircraft may encounter 32 [deg]F 
temperature or lower and it seems arbitrary to disallow the use of data 
that has already been approved and in use for over two years. Operators 
would have the burden of requesting the same AMOC for the superseding 
AD. Allowing the currently approved AMOCs would bridge the time gap to 
the Terminating Action compliance date.
    We agree. We changed Alternative Methods of Compliance (AMOC), 
paragraph (l) from ``AMOCs approved for AD 99-02-51 are not approved as 
AMOCs for this AD.'' to ``AMOCs currently approved for AD 99-02-51 will 
remain in effect until the terminating action date for this AD, 
September 30, 2009. After that date, these AMOCs will expire and not be 
approved as AMOCs for this AD.'' This change will avoid confusion in 
the field and the AMOCs are still appropriate for the period before the 
mandatory terminating action date. These AMOCs will expire permanently 
on September 30, 2009, after which the only allowable configuration 
option is the new seal, a compatible starter and an open seal drain.

Request To Provide a More Accurate Description of the Original Problem

    Two commenters, RRC and Embraer, ask us to include a more accurate 
description of the original problem. They state that the nomenclature 
``Starter shaft seal'' may cause confusion with the seal of the 
pneumatic Air Turbine Starter (ATS). We agree. We changed Unsafe 
Condition, paragraph (d) from ``* * * due to loss of engine oil from 
the starter shaft seal'' to ``* * * due to loss of engine oil from the 
engine accessory gearbox starter pad shaft seal drain and possible loss 
of the airplane.''

Request To Clarify the Regulatory Text

    Rolls-Royce Corporation asks us to make the following changes for 
clarity:
     Prohibited Flights, paragraph (f)(2): Change ``Oil 
consumption greater than 0.32 quart per hour (303 cc per hour) * * *'' 
to ``Oil consumption greater than 0.32 quart per hour, or 300 cc per 
hour, * * *'' Although it may not be a completely accurate quart-to-cc 
conversion, 300 cc is the value listed in all RRC manuals.
     Terminating Action, paragraph (g): Change ``* * * do the 
following, as applicable to your engine model and configuration.'' to 
``* * * do the following, as applicable to your configuration.'' Engine 
model applicability is already established so it can be deleted here to 
make a simpler statement.
     Terminating Action, paragraph (g)(1): Change ``Remove seal 
part number (P/N) * * * '' to ``Remove seal and related component part 
numbers (P/Ns) * * *'' The P/Ns listed are not only currently approved 
seals but also adjacent hardware including a wave spring and spacer 
used in one of the approved configurations. This change accounts for 
all current hardware, not just the seals.
     Terminating Action, paragraph (g)(2): Change ``Install a 
new seal, P/N AS3209-026 * * *'' to ``Install a new O-ring, P/N AS3209-
026 or M83248/1-026* * *'' RRC lists both of these P/Ns as acceptable 
alternatives in the engine parts list. Also, the correct nomenclature 
is O-ring, not seal.
     Prohibition of Seals, paragraph (i): Change ``Once the 
terminating action in this AD is performed on an engine, seal P/Ns * * 
*'' to ``Once the terminating action in this AD is performed on an 
engine, seal and related component P/Ns * * *'' This change accounts 
for all current hardware, not just the seals.
    We agree with the suggestions and incorporated them into the 
applicable regulatory text of the AD.

Request to Not Implement the AD

    Rolls-Royce North America, Inc., c/o American Eagle Airlines, asks 
us to not implement the AD, or at least extend the required completion 
date for the terminating action by at least 6-12 months. They believe 
that many AE3007A and AE3007C engines are not yet compliant with RRC 
Service Bulletin AE 3007A-72-321 and or SB AE 3007A-72-330. They state 
that it would be too much of a burden to modify all of the engines 
currently out in the field to be compliant with the proposed AD by 
September 30, 2009. A drastic maintenance campaign such as this would 
adversely affect the AE3007A and C fleet both in terms of costs and 
operations to drastic proportions.
    We don't agree. We have determined that we can better assure long-
term continued operational safety by design changes that remove the 
source of the problem, rather than by repetitive inspections or other 
special procedures. Based on the availability of the required parts and 
the support from the vast majority of operators and their ability to 
comply within the original specified date, we believe this is a 
reasonable time period and will maintain the final compliance date of 
September 30, 2009.

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 1,868 RRC AE 3007A and AE 
3007C series turbofan engines installed on aircraft of U.S. registry. 
We also estimate that it will take about 4 work-hours per engine to 
perform the proposed terminating action, and that the average labor 
rate is $80 per work-hour. Required parts will cost about $2,917 per 
engine. Based on these figures, if all engines incorporated the 
terminating action, we estimate the total cost of this AD to U.S. 
operators to be $6,046,100.

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

[[Page 67244]]

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.

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 removing Amendment 39-11108 64 FR 
16339 April 5, 1999, and by adding a new airworthiness directive, 
Amendment 39-15271, to read as follows:

2007-24-05 Rolls-Royce Corporation (Formerly Allison Engine Company, 
Inc.): Amendment 39-15271. Docket No. FAA-2007-26966; Directorate 
Identifier 99-NE-01-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective January 
2, 2008.

Affected ADs

    (b) This AD supersedes AD 99-02-51, Amendment 39-11108.

Applicability

    (c) This AD applies to Rolls-Royce Corporation (RRC) (formerly 
Allison Engine Company, Inc.) AE 3007A and AE 3007C series turbofan 
engines. These engines are installed on, but not limited to, Cessna 
Aircraft Company 750 series, and Empresa Brasileira de Aeronautica 
S. A. (EMBRAER) EMB-135 and EMB-145 series airplanes.

Unsafe Condition

    (d) This AD results from design improvements to components in 
the accessory gearbox air turbine starter mounting pad. We are 
issuing this AD to prevent an in-flight engine shutdown due to loss 
of engine oil from the starter shaft seal and possible loss of 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.

Prohibited Flights

    (f) All flights after ground engine starts at engine oil 
temperatures below 32 [deg]F (0 [deg]C), are prohibited except as 
follows:
    (1) If the engine oil temperature has dropped below 32 [deg]F (0 
[deg]C), before flight, perform a high-power leak check on each 
engine (at least three minutes at takeoff power).
    (2) Oil consumption greater than 0.32 quart per hour, or 300 cc 
per hour, is not permitted. Instructions for performing the high-
power leak check for the AE 3007A series engines can be found in the 
Rolls-Royce AE 3007A Series Maintenance Manual, TASK 72-00-00-700-
801, SUBTASK 72-00-00-790-002. Leak check limits for the AE 3007A 
series engines can be found in the Rolls-Royce AE 3007A Series 
Maintenance Manual, TASK 71-00-00-200-801.
    (3) Instructions for performing the high-power leak check for 
the AE 3007C series engines (including leak check limits) can be 
found in the Rolls-Royce AE 3007C Series Maintenance Manual, TASK 
72-00-00-700-801, SUBTASK 72-00-00-790-002.

Terminating Action

    (g) No later than September 30, 2009, as terminating action to 
the requirements in paragraph (f) through (f)(3) of this AD, do the 
following, as applicable to your engine configuration:
    (1) Remove seal and related component, part numbers (P/Ns) 
42520-71, 42520-196-X, 99004-1-6, 42520-75, or 42520-167, from the 
accessory gearbox (AGB) air turbine starter mounting pad.
    (2) Install a new O-ring, P/N AS3209-026, M83248/1-026 or other 
serviceable part, to the shaft of the starter mounting pad.
    (3) Install a new bearing locknut, P/N 42520-170, or other 
serviceable part, and an AGB air turbine starter mounting pad 
mechanical seal, P/N 42520-192, or other serviceable part.
    (4) Use paragraphs 2. through 2.G. of the Accomplishment 
Instructions of RRC Service Bulletin (SB) No. AE 3007A-72-321/AE 
3007C-72-250, Revision 2, dated November 12, 2007, to do the 
removals and installations.
    (5) For AE 3007A series engines, remove the drain cap or starter 
drain adapter. Use paragraphs 2. through 2.C.(4)(c) of the 
Accomplishment Instructions of RRC SB No. AE 3007A-72-274, Revision 
1, dated November 12, 2007 to do the removal.
    (6) For AE 3007A series engines, install an open starter drain 
adapter. Use paragraphs 2. through 2.C.(2) of the Accomplishment 
Instructions of RRC SB No. AE 3007A-72-330, Revision 1, dated 
November 12, 2007 to do the installation.
    (7) For AE 3007C series engines, install an open starter drain 
adapter. Use paragraphs 2. through 2.E.(2) of the Accomplishment 
Instructions of RRC SB No. AE 3007C-72-223, Revision 1, dated 
November 12, 2007 to do the installation.

Definition

    (h) A serviceable part is any FAA-approved part not being 
removed from service, or not otherwise specifically addressed by 
this AD action.

Prohibition of Seals

    (i) Do not install seal and related component P/Ns 42520-71, 
42520-196-X, 99004-1-6, 42520-75, and 42520-167, on the air starter 
mounting pad after the terminating action in this AD is performed.

Previous Credit

    (j) Previous credit is allowed for the terminating action in 
paragraphs (g)(1) through (g)(7) of this AD, that was done before 
the effective date of this AD using the Accomplishment Instructions 
of the SBs listed in the following Table 1:

                 Table 1.--SBs Allowing Previous Credit
------------------------------------------------------------------------

-------------------------------------------------------------------------
For AE 3007A Series Engines:
    (1) Engine--Accessory Drive Gearbox Assembly--New Starter Shaft
     Seal; RRC SB No. AE 3007A-72-321/AE 3007C-72-250, Revision 1, dated
     November 7, 2005; and
    (2) Engine--Accessory Gearbox Starter Pad Drain--Remove The Drain
     Cap or Starter Drain Adapter; RRC SB No. AE 3007A-72-274, dated
     January 19, 2006; and
    (3) Engine--Accessory Gearbox Starter Pad Drain--Install the Open
     Starter Drain Adapter (23083402 or 23077526); RRC SB No. AE 3007A-
     72-330, dated January 19, 2006.
For AE 3007C Series Engines:
    (4) Engine--Accessory Drive Gearbox Assembly--New Starter Shaft
     Seal; RRC SB No. AE 3007A-72-321/AE 3007C-72-250, Revision 1, dated
     November 7, 2005; and

[[Page 67245]]

    (5) Engine--Accessory Gearbox Starter Pad Drain--Install the Open
     Starter Drain Adapter (23077526 or 23083403); RRC SB No. AE 3007C-
     72-223, dated January 19, 2006.
------------------------------------------------------------------------

Alternative Methods of Compliance (AMOC)

    (k) The Manager, Chicago Aircraft Certification Office, has the 
authority to approve AMOCs for this AD if requested using the 
procedures found in 14 CFR 39.19.
    (l) AMOCs currently approved for AD 99-02-51 will remain in 
effect until the terminating action date for this AD, September 30, 
2009. After that date, these AMOCs will expire and will not be 
approved as AMOCs for this AD.

Related Information

    (m) Contact Kyri Zaroyiannis, Aerospace Engineer, Chicago 
Aircraft Certification Office, Small Airplane Directorate, FAA, 2300 
E. Devon Ave., Des Plaines, IL 60018; e-mail: 
kyri.zaroyiannis@faa.gov; telephone (847) 294-7836; fax (847) 294-
7834, for more information about this AD.

Material Incorporated by Reference

    (n) You must use the service information specified in Table 2 to 
perform the actions required by this AD. The Director of the Federal 
Register approved the incorporation by reference of the documents 
listed in Table 2 of this AD in accordance with 5 U.S.C. 552(a) and 
1 CFR part 51. Contact Rolls-Royce Corporation, P.O. Box 420, 
Indianapolis, IN 46206; telephone (317) 230-3774; fax (317) 230-
8084; e-mail: indy.pubs.services@rolls-royce.com, 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 2.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
      Service Bulletin No.                     Page                  Revision                  Date
----------------------------------------------------------------------------------------------------------------
AE 3007A-72-274.................  ALL...........................               1  November 12, 2007.
    Total Pages--6
AE 3007A-72-321, AE 3007C-72-250  ALL...........................               2  November 12, 2007.
    Total Pages--13
AE 3007A-72-330.................  ALL...........................               1  November 12, 2007.
    Total Pages--6
AE 3007C-72-223.................  ALL...........................               1  November 12, 2007.
  Total Pages--7
----------------------------------------------------------------------------------------------------------------

    Issued in Burlington, Massachusetts, on November 14, 2007.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E7-22810 Filed 11-27-07; 8:45 am]

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