Document ID: FAA-2009-1100-0033
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: International Aero Engines AG Turbofan Engines
Posted Date: 2014-12-24T05:00Z

[Federal Register Volume 79, Number 247 (Wednesday, December 24, 2014)]
[Proposed Rules]
[Pages 77411-77413]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2014-30194]

 ========================================================================
 Proposed Rules
                                                 Federal Register
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 This section of the FEDERAL REGISTER contains notices to the public of 
 the proposed issuance of rules and regulations. The purpose of these 
 notices is to give interested persons an opportunity to participate in 
 the rule making prior to the adoption of the final rules.
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  Federal Register / Vol. 79, No. 247 / Wednesday, December 24, 2014 / 
Proposed Rules  

[[Page 77411]]

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-1100; Directorate Identifier 2009-NE-37-AD]
RIN 2120-AA64

Airworthiness Directives; International Aero Engines AG Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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

SUMMARY: We propose to supersede airworthiness directive (AD) 2012-09-
09 that applies to 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. AD 2012-09-09 currently requires 
cleaning, eddy current inspection (ECI) or fluorescent penetrant 
inspection (FPI), and initial and repetitive ultrasonic inspections 
(USIs) of certain high-pressure compressor (HPC) stage 3 to 8 drums, as 
well as replacement of the drum attachment nuts. Since we issued AD 
2012-09-09, we discovered that additional attachment nuts for certain 
HPC stage 3 to 8 drums are affected. This proposed AD would expand the 
affected population for initial and repetitive USIs of the HPC stage 3 
to 8 drum, revise the inspection intervals, require removal of the 
affected attachment nuts and any HPC stage 3 to 8 drum found cracked, 
and require a mandatory terminating action. We are proposing this AD to 
prevent failure of the HPC stage 3 to 8 drum, which could result in 
uncontained drum failure, damage to the engine, and damage to the 
airplane.

DATES: We must receive comments on this proposed AD by February 23, 
2015.

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 NPRM, contact 
International Aero Engines AG, 400 Main Street, East Hartford, CT 
06118; phone: 860-368-3700; fax: 860-368-4600; email: 
iaeinfo@iaev2500.com; Internet: https://www.iaeworld.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 by searching for and locating Docket No. FAA-2009-
1100; 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 NPRM, 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: Martin Adler, Aerospace Engineer, 
Engine Certification Office, FAA, Engine & Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803; phone: 781-238-7157; 
fax: 781-238-7199; email: martin.adler@faa.gov.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this NPRM. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2009-1100; 
Directorate Identifier 2009-NE-37-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this NPRM. We will 
consider all comments received by the closing date and may amend this 
NPRM 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 NPRM.

Discussion

    On May 2, 2012, we issued AD 2012-09-09, Amendment 39-17044 (77 FR 
30371, May 23, 2012), (``AD 2012-09-09''), for 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. AD 2012-09-09 requires cleaning, ECI or FPI, and 
initial and repetitive USIs of certain HPC stage 3 to 8 drums, as well 
as replacement of the drum attachment nuts. AD 2012-09-09 resulted from 
inspections that found 50 HPC drums with cracks and reports that 
indicated that the required inspection intervals were not adequate. We 
issued AD 2012-09-09 to prevent uncontained failure of the HPC stage 3 
to 8 drum, which could result in damage to the airplane.

Actions Since AD 2012-09-09 Was Issued

    Since we issued AD 2012-09-09, we discovered that partially silver-
plated nuts for certain HPC stage 3 to 8 drums cause the drum to 
corrode and crack. IAE has also developed a new nut design without 
silver plating.

Relevant Service Information

    We reviewed IAE Alert Non-Modification Service Bulletin (NMSB) No. 
V2500-ENG-72-0615, Revision 6, dated September 4, 2014; IAE NMSB No. 
V2500-ENG-72-0625, dated September 20, 2011; and IAE NMSB No. V2500-
ENG-72-0637, dated May 2, 2013. IAE Alert NMSB No. V2500-ENG-72-0615 
describes procedures for performing a USI of the HPC stage 3 to 8 drum. 
IAE NMSB No. V2500-ENG-72-0625 provides guidance on performing an ECI 
that will improve the ability to detect cracked HPC stage 3 to 8 drums. 
IAE NMSB No. V2500-ENG-72-0637 describes procedures for

[[Page 77412]]

performing an FPI of the HPC stage 3 to 8 drum.

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 expand the affected population for initial 
and repetitive USIs of the HPC stage 3 to 8 drum, revise the inspection 
intervals, require removal of affected attachment nuts, and require 
removal of any HPC stage 3 to 8 drums found cracked. As mandatory 
terminating action, this proposed AD would require installation of an 
HPC stage 3 to 8 drum that has never operated with silver-plated nuts 
using silver-free nuts to attach the HPC stage 3 to 8 drum to the HPC 
stage 9 to 12 drum.

Costs of Compliance

    We estimate that this proposed AD affects 956 engines installed on 
airplanes of U.S. registry. We estimate that it would take about 3 
hours per engine to perform the USI and about 2 hours per engine to 
perform the FPI or ECI of the HPC stage 3 to 8 drum. We also estimate 
that removing silver residue from the HPC stage 3 to 8 drum would cost 
about $2,600 per engine, and required parts would cost about $1,060 per 
engine. We estimate the pro-rated replacement cost to replace an HPC 
stage 3 to 8 drum to be $52,014. Based on these figures, we estimate 
the cost of this proposed AD on U.S. operators to be $53,630,644.

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 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) 
2012-09-09, Amendment 39-17044 (77 FR 30371, May 23, 2012), and adding 
the following new AD:

International Aero Engines AG: Docket No. FAA-2009-1100; Directorate 
Identifier 2009-NE-37-AD.

(a) Comments Due Date

    The FAA must receive comments on this AD action by February 23, 
2015.

(b) Affected ADs

    This AD replaces AD 2012-09-09, Amendment 39-17044 (77 FR 30371, 
May 23, 2012).

(c) Applicability

    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) 
V10001 through V13190, and V15001 through V16728, excluding V16707.

(d) Unsafe Condition

    This AD was prompted by the discovery that additional attachment 
nuts for certain HPC stage 3 to 8 drums cause the drum to corrode 
and crack. We are issuing this AD to prevent failure of the HPC 
stage 3 to 8 drum, which could result in uncontained drum failure, 
damage to the engine, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done. Use paragraph 3.A. of IAE Alert Non-
Modification Service Bulletin (NMSB) No. V2500-ENG-72-A0615, 
Revision 6, dated September 4, 2014, to do the ultrasonic inspection 
(USI) required by this AD. You may use the inspections listed in 
paragraph (g)(3) of this AD instead of a USI for the initial 
inspection required by paragraphs (e)(1) through (e)(5) of this AD. 
If cracks are found during any of the inspections required by this 
AD, remove the drum from service before further flight.
    (1) Initial USI of the HPC stage 3 to 8 drum--Group ``A'' and 
Group ``B'':
    For IAE V2500-A1 turbofan engines with S/Ns listed in ``Group 
A'' or ``Group B'' in paragraph 1.E. in IAE Alert NMSB No. V2500-
ENG-72-A0615, Revision 6, dated September 4, 2014, perform an 
initial USI of the HPC stage 3 to 8 drum within 200 cycles of 
accumulating 8,000 cycles-since-new (CSN) or within 200 cycles from 
the effective date of this AD, whichever occurs later.
    (2) Initial USI of the HPC stage 3 to 8 drum--Group ``C'':
    For IAE V2500-A5 turbofan engines with S/Ns listed in ``Group 
C'' in paragraph 1.E. in IAE Alert NMSB No. V2500-ENG-72-A0615, 
Revision 6, dated September 4, 2014, perform an initial USI of the 
HPC stage 3 to 8 drum within 200 cycles of accumulating 6,250 CSN or 
within 200 cycles from the effective date of this AD, whichever 
occurs later.
    (3) Initial USI of the HPC stage 3 to 8 drum--Group ``D'':
    For IAE V2500-A5 turbofan engines with S/Ns listed in ``Group 
D'' in paragraph 1.E. in IAE Alert NMSB No. V2500-ENG-72-A0615, 
Revision 6, dated September 4, 2014, perform an initial USI of the 
HPC stage 3 to 8 drum within 200 cycles of accumulating 3,750 CSN or 
within 200 cycles from the effective date of this AD, whichever 
occurs later.
    (4) Initial USI of the HPC stage 3 to 8 drum--Group ``E'':
    For IAE V2500-A1, -A5, and -D5 turbofan engines not listed in 
``Group A,'' ``Group B,'' ``Group C,'' or ``Group D,'' and with drum 
assembly part numbers (P/Ns) listed in ``Group E'' in paragraph 1.E. 
in IAE Alert NMSB No. V2500-ENG-72-A0615, Revision

[[Page 77413]]

6, dated September 4, 2014, perform an initial USI of the HPC stage 
3 to 8 drum within 200 cycles of accumulating 12,500 CSN or within 
200 cycles from the effective date of this AD, whichever occurs 
later.
    (5) Initial USI of the HPC stage 3 to 8 drum--Group ``F'':
    For IAE V2500-A1, -A5, and -D5 turbofan engines not listed in 
``Group A,'' ``Group B,'' ``Group C,'' or ``Group D,'' and with drum 
assembly P/Ns listed in ``Group F'' in paragraph 1.E. in IAE Alert 
NMSB No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014, 
perform an initial USI of the HPC stage 3 to 8 drum within 200 
cycles of accumulating 9,000 CSN or within 200 cycles from the 
effective date of this AD, whichever occurs later.

(f) Repetitive USIs of the HPC Stage 3 to 8 Drum

    (1) For engines included in ``Group A,'' ``Group B,'' ``Group 
C,'' ``Group E,'' or ``Group F,'' as defined in paragraph (e) of 
this AD, perform repetitive USIs of the HPC stage 3 to 8 drum within 
every 750 cycles of the last USI.
    (2) For engines included in ``Group D,'' as defined in paragraph 
(e) of this AD, perform repetitive USIs of the HPC stage 3 to 8 drum 
within every 500 cycles of the last USI.
    (3) If you inspect the HPC stage 3 to 8 drum at shop visit, you 
may delay the next USI as shown in the ``Grace Periods Table'' for 
each compliance group listed in paragraph 1.E. in IAE Alert NMSB No. 
V2500-ENG-72-A0615, Revision 6, dated September 4, 2014.

(g) Removal of Silver-Plated Nuts

    Unless already done, 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 any HPC stage 3 to 8 drum to service:
    (1) Remove from service all silver-plated nuts (fully or 
partially-plated), P/Ns AS44862 or AS64367, 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.
    (3) Perform an inspection of the HPC stage 3 to 8 drum using at 
least one of the following methods:
    (i) Fluorescent penetrant inspection (FPI) of the HPC stage 3 to 
8 drum for cracks, or
    (ii) Eddy current inspection (ECI) of the HPC stage 3 to 8 drum 
for cracks.

(h) Installation Prohibition

    After the effective date of this AD, do not install any silver-
plated nuts, P/N AS44862 or AS64367, into any engine.

(i) Mandatory Terminating Action

    Within 9,450 cycles after the effective date of this AD, 
install:
    (1) an HPC stage 3 to 8 drum that has never operated with 
silver-plated nuts (fully or partially plated) to attach the HPC 
stage 3 to 8 drum to the HPC stage 9 to 12 drum, with
    (2) silver-free nuts to attach the HPC stage 3 to 8 drum to the 
HPC stage 9 to 12 drum.

(j) Definition

    For the purpose of this AD, ``piece-part exposure'' is removal 
of the HPC stage 3 to 8 drum from the engine, removal of all blades 
from the drum, and separation of the HPC stage 3 to 8 drum from the 
stage 9 to 12 drum.

(k) Credit for Previous Actions

    If you performed an inspection of the HPC stage 3 to 8 drum 
before the effective date of this AD using one of the following IAE 
NMSBs, you met the initial inspection requirement of paragraph (e) 
of this AD:
    (i) IAE NMSB No. V2500-ENG-72-0594, Revision 3, dated August 7, 
2009, through Revision 6, dated April 12, 2010.
    (ii) IAE NMSB No. V2500-ENG-72-0603, Revision 2, dated March 17, 
2010, or earlier revisions.
    (iii) IAE NMSB No. V2500-ENG-72-0608, Revision 3, dated 
September 20, 2011, or earlier revisions.
    (iv) IAE NMSB No. V2500-ENG-72-0615, Revision 5, dated August 5, 
2014, or earlier revisions.
    (v) IAE NMSB No. V2500-ENG-72-0638, Initial Issue, dated April 
11, 2013.

(l) Alternative Methods of Compliance (AMOCs)

    The Manager, Engine Certification Office, FAA, may approve AMOCs 
for this AD. Use the procedures found in 14 CFR 39.19 to make your 
request. You may email your request to: ANE-AD-AMOC@faa.gov.

(m) Related Information

    (1) For more information about this AD, contact Martin Adler, 
Aerospace Engineer, Engine Certification Office, FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, MA 
01803; phone: 781-238-7157; fax: 781-238-7199; email: 
martin.adler@faa.gov.
    (2) IAE NMSB No. V2500-ENG-72-0637, dated May 2, 2013; IAE NMSB 
No. V2500-ENG-72-0625, dated September 20, 2011; IAE Engine Manual 
Task 72-41-11-200-001; and IAE Engine Manual Task 72-41-11-110-001, 
which are not incorporated by reference in this AD, can be obtained 
from IAE, using the contact information in paragraph (m)(3) of this 
proposed AD. IAE NMSB No. V2500-ENG-72-0637 and IAE Engine Manual 
Task 72-41-11-200-001 provide guidance on performing the FPI. 
Guidance on performing the ECI can be found in IAE NMSB No. V2500-
ENG-72-0625. IAE Engine Manual Task 72-41-11-110-001 provides 
guidance on cleaning the HPC stage 3 to 8 drum.
    (3) For service information identified in this AD, contact 
International Aero Engines AG, 400 Main Street, East Hartford, CT 
06118; phone: 860-368-3700; fax: 860-368-4600; email: 
iaeinfo@iaev2500.com; Internet: https://www.iaeworld.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 December 16, 2014.
Colleen M. D'Alessandro,
Assistant Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2014-30194 Filed 12-23-14; 8:45 am]
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