Document ID: FAA-2011-0945-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Honeywell International Inc. Turbofan Engines
Posted Date: 2012-01-09T05:00Z

[Federal Register Volume 77, Number 5 (Monday, January 9, 2012)]
[Proposed Rules]
[Pages 1043-1045]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2012-80]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2011-0945; Directorate Identifier 2011-NE-18-AD]
RIN 2120-AA64

Airworthiness Directives; Honeywell International Inc. Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to adopt a new airworthiness directive (AD) for the 
products identified above. This proposed AD was prompted by a report of 
a quality escape of about 8,000 2nd stage low pressure turbine (LPT2) 
rotor blades, manufactured by Honeywell Chihuahua Manufacturing 
Operation since 2009. This proposed AD would require removing and 
inspecting certain LPT2 rotor blades. During LPT rotor acceleration, 
these blades may contact and damage the 3rd stage LPT (LPT3) nozzle 
seal carrier, which may subsequently fatigue and contact the adjacent 
rotor and damage the rotor. Also, these blades could deform the blade 
retainers, which could lead to blade movement that may cause rotor 
damage. We are proposing this AD to correct an unsafe condition caused 
by these blades installed on these engines.

DATES: We must receive comments on this proposed AD by March 9, 2012.

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 
Honeywell International Inc., 111 S. 34th Street, Phoenix, AZ 85034-
2802; web site: http://portal.honeywell.com; or call Honeywell toll 
free at phone: (800) 601-3099 (U.S./Canada) or (602) 365-3099 
(International Direct). You may review copies of the referenced service 
information at the FAA, Engine & Propeller Directorate, 12 New England 
Executive Park, Burlington, MA 01803. 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: Joseph Costa, Aerospace Engineer, Los 
Angles Aircraft Certification Office, FAA, Transport Airplane 
Directorate, 3960 Paramount Blvd., Lakewood, CA 90712-4137; phone: 
(562) 627-5246; fax: (562) 627-5210; email: joseph.costa@faa.gov.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2011-0945; 
Directorate Identifier 2011-NE-18-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

    During a routine replacement of LPT2 rotor blades, part numbers (P/
Ns) 3075424-2 and 3075424-3, the new LPT2 rotor blades, P/Ns 3075424-2 
and 3075424-3, were seen to have aft discouragers that were 
approximately 0.020 inch (0.51 mm) longer than the existing LPT2 rotor 
blades, P/Ns 3075424-2 and 3075424-3. Further investigation revealed 
that the aft discouragers of the new LPT2 rotor blades, P/Ns 3075424-2 
and 3075424-3, did not meet the type design requirements. That 
investigation also found that only LPT2 rotor blades P/Ns 3075424-2 and 
3075424-3, manufactured from specific machining lots, are affected. P/N 
3075424-2 suspect lots were manufactured between March 2009 and 
September 2010, inclusive. P/N 3075424-3 suspect lots were manufactured 
between July 2010 and September 2010, inclusive.
    During LPT rotor acceleration, these blades may contact and damage 
the LPT3 nozzle seal carrier, which may subsequently fatigue and 
contact the adjacent rotor and damage the rotor. Also, these blades 
could deform the blade retainers, which could lead to blade movement 
that may cause rotor damage.
    We have not received any reports of engine in-flight shutdowns due 
to these blades being in service.
    These blades may damage the rotor. This condition, if not 
corrected, could result in damage to these blades installed on these 
engines.

[[Page 1044]]

Relevant Service Information

    Honeywell International Inc. Service Bulletin (SB) TFE731-72-5221, 
Revision 0, dated November 11, 2010 describes procedures for 
determining affected engine serial numbers (S/Ns) and machining lot of 
affected LPT2 rotor blades.

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 other products of the same type design.

Proposed AD Requirements

    This proposed AD would require removing and inspecting suspect LPT2 
rotor blades:
     At the next major periodic inspection, not to exceed 3,000 
hours time-since-new, or
     Five years after the effective date of this proposed AD, 
or
     When the LPT module is disassembled.

Costs of Compliance

    We estimate that this proposed AD would affect 3,000 engines 
installed on airplanes of U.S. registry. We also estimate that it would 
take about 1 work-hour per engine to perform the record review, and 
that the average labor rate is $85 per work-hour. For an estimated 500 
engines with discrepant blades, blade rework cost was estimated at 
$2,380 per engine with a replacement parts cost about $1,100 per 
engine. Based on these figures, we estimate the total cost of the 
proposed AD to U.S. operators to be $1,430,100.

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 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 this 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, 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

    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]

    2. The FAA amends Sec.  39.13 by adding the following new 
airworthiness directive (AD):

Honeywell International Inc. (Formerly Allied Signal Inc. and 
Garrett Turbine Engine Company): Docket No. FAA-2011-0945; 
Directorate Identifier 2011-NE-18-AD.

(a) Comments Due Date

    We must receive comments by March 9, 2012.

(b) Affected ADs

    None.

(c) Applicability

    (1) This AD applies to Honeywell International Inc. TFE731-20R, 
-20AR, -20BR, -40, -40AR, -40R, -50R, and -60 turbofan engines.
    (i) With an engine model number and serial number (S/N) listed 
in Table 4 of Honeywell Service Bulletin (SB) TFE731-72-5221, 
Revision 0, dated November 11, 2010, or
    (ii) With 2nd stage low pressure turbine (LPT2) rotor assembly 
part numbers (P/Ns) 3060608-2, 3060608-3, or 3060608-5 that had any 
LPT2 rotor blades P/N 3075424-2 replaced between March 2009 and 
September 2010, inclusive, or that had any LPT2 rotor blades P/N 
3075424-3 replaced between July 2010 and September 2010, inclusive.

(d) Unsafe Condition

    This AD was prompted by a report of a quality escape of about 
8,000 LPT2 rotor blades, manufactured by Honeywell Chihuahua 
Manufacturing Operation since 2009. During LPT rotor acceleration, 
these blades may contact and damage the 3rd stage LPT (LPT3) nozzle 
seal carrier that may subsequently fatigue and contact the adjacent 
rotor and damage the rotor. Also, these blades could deform the 
blade retainers, which could lead to blade movement that may cause 
rotor damage. We are issuing this AD to correct the unsafe condition 
caused by these blades installed on these engines.

(e) Compliance

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

(f) Remove LPT2 Rotor Blades

    (1) At the next major periodic inspection, not to exceed 3,000 
hours time-since-new, or within 5 years after the effective date of 
this AD, or at the next access, whichever occurs first, do the 
following using Section 3.0, Accomplishment Instructions, of 
Honeywell SB TFE731-72-5221, Revision 0, dated November 11, 2010:
    (i) Remove any suspect LPT2 rotor blades from service.
    (ii) Inspect suspect LPT2 rotor blades.

(g) Alternative Methods of Compliance (AMOCs)

    The Manager, Los Angeles Certification Office, FAA, may approve 
AMOCs to this AD. Use the procedures found in 14 CFR 39.19 to make 
your request.

(h) Definitions

    For purposes of this AD, next access is defined as when the LPT 
module is disassembled.

(i) Related Information

    (1) For more information about this AD, contact Joseph Costa, 
Aerospace Engineer, Los Angles Aircraft Certification Office, FAA, 
Transport Airplane Directorate, 3960 Paramount Blvd. Lakewood, CA 
90712-4137; phone: (562) 627-5246; fax: (562) 627-5210; email: 
joseph.costa@faa.gov.
    (2) For service information identified in this AD, contact 
Honeywell International Inc., 111 S. 34th Street, Phoenix, AZ 85034-
2802; Web site: http://portal.honeywell.com; or call Honeywell toll 
free at phone: (800) 601-3099 (U.S./Canada) or (602) 365-3099 
(International Direct). You may review copies of the referenced 
service information at the FAA, Engine & Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803. For information on 
the availability of this material at the FAA, call (781) 238-7125.

[[Page 1045]]

    Issued in Burlington, Massachusetts, on December 29, 2011.
Peter A. White,
Manager, Engine & Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 2012-80 Filed 1-6-12; 8:45 am]
BILLING CODE 4910-13-P