Document ID: FAA-2009-1100-0017
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: International Aero Engines AG Turbofan Engines
Posted Date: 2011-12-30T05:00Z

[Federal Register Volume 76, Number 251 (Friday, December 30, 2011)]
[Proposed Rules]
[Pages 82202-82204]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2011-33536]

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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).

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SUMMARY: We propose to supersede an existing airworthiness directive 
(AD), for 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. The existing AD currently requires initial 
and repetitive on-wing ultrasonic inspections (USIs) of certain high-
pressure compressor (HPC) stage 3 to 8 drums, and replacement of drum 
attachment nuts. This proposed AD would expand the affected population 
for initial and repetitive on-wing inspections of the HPC stage 3 to 8 
drum, introduce an eddy current inspection (ECI) procedure, and require 
additional cleaning and repetitive on-wing USI or ECI of some HPC stage 
3 to 8 drums. We are proposing this AD to prevent failure of the HPC 
stage 3 to 8 drum, uncontained engine failure, and damage to the 
airplane.

DATES: We must receive comments on this proposed AD by February 28, 
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 AD, contact 
International Aero Engines AG, 628 Hebron Avenue, Suite 400, 
Glastonbury, CT 06033; phone: (860) 368-3700; fax: (860) 368-4600; e-
mail: iaeinfo@iaev2500.com; Web site: https://www.iaeworld.com. 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: Carlos Fernandes, Aerospace Engineer, 
Engine Certification Office, FAA, Engine & Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803; phone: (781) 238-
7189; fax: (781) 238-7199; email: carlos.fernandes@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-2009-1100; 
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 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 15, 2010, we issued AD 2010-20-07, Amendment 39-16441 
(75 FR 59067, September 27, 2010), for 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. That AD requires initial and repetitive on-wing USI of the HPC 
stage 3 to 8 drum for cracks for certain S/Ns of V2500-A1, V2522-A5, 
V2524-A5, V2527-A5,

[[Page 82203]]

V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 series turbofan engines. 
As mandatory terminating action to the repetitive inspections, that AD 
requires removal from service of the fully silver plated nuts attaching 
the HPC stage 3 to 8 drum to the HPC stage 9 to 12 drum, removal of 
silver residue from the HPC stage 3 to 8 drum, and FPI of the stage 3 
to 8 drum within a specified time. For all other engines, that AD 
requires removal from service of the fully silver plated nuts attaching 
the HPC stage 3 to 8 drum to the HPC stage 9 to 12 drum, removal of 
silver residue from the HPC stage 3 to 8 drum, and FPI of the HPC stage 
3 to 8 drum at the next drum piece-part exposure. That AD resulted from 
reports of 39 HPC stage 3 to 8 drums found cracked since March 2009. We 
issued that AD to prevent failure of the HPC stage 3 to 8 drum, 
uncontained engine failure, and damage to the airplane.

Actions Since Existing AD Was Issued

    Since we issued AD 2010-20-07 (75 FR 59067, September 27, 2010), 
inspections have found 50 additional HPC drums with cracks. Some 
reports have indicated that the FPI may miss small cracks. This has 
necessitated the expansion of the compliance requirements.

Relevant Service Information

    We reviewed IAE Service Bulletin (SB) V2500-ENG-72-0615, Revision 
3, dated September 20, 2011. That SB will replace IAE SB V2500-ENG-72-
0594, Revision 6, dated April 12, 2010 and IAE SB V2500-ENG-72-0603, 
Revision 1, dated February 17, 2011. We have also reviewed IAE SB No. 
V2500-ENG-72-0601, Revision 2, dated April 12, 2010. That SB describes 
procedures for removing the silver residue from the HPC stage 3 to 8 
drum. We have also reviewed IAE SB V2500-ENG-72-0615, Revision 3, dated 
September 20, 2011 and IAE SB No. V2500-ENG-72-0608, Revision 3, dated 
September 20, 2011. Those SBs describe procedures for performing USIs 
of the HPC stage 3 to 8 drum. We have also reviewed IAE SB V2500-ENG-
72-0625, dated September 20, 2011 which introduces an ECI procedure 
that will improve the ability to detect cracks of the HPC 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 retain certain requirements of AD 2010-20-
07. The proposed AD has the same applicability requirements as AD 2010-
20-07. This proposed AD, however, would expand the initial and 
repetitive on-wing USIs of the HPC stage 3 to 8 drum for cracks to a 
larger population of S/Ns of V2500-A1, V2522-A5, V2524-A5, V2527-A5, 
V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 turbofan engines and all 
V2525-D5 and V2528-D5 turbofan engines. This proposed AD would 
introduce an ECI procedure that will improve the ability to detect 
cracks of the HPC stage 3 to 8 drum. This proposed AD would require 
repetitive on-wing USI of the HPC stage 3 to 8 drum after removal from 
service of all of the fully silver plated nuts attaching the HPC stage 
3 to 8 drum to the HPC stage 9 to 12 drum; removal of silver residue 
from the HPC stage 3 to 8 drum; and FPI or ECI of the stage 3 to 8 
drum. This proposed AD would also remove the mandatory terminating 
action and replace it with an optional terminating action.

Costs of Compliance

    We estimate that this proposed AD would affect about 906 IAE V2500-
A1, V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, 
V2528-D5, V2530-A5, and V2533-A5 turbofan engines installed on 
airplanes of U.S. registry. We estimate that 906 of these engines would 
require USIs, and that it would take about 3 work-hours per engine to 
perform one USI. We estimate that it would take about 2 work-hours per 
engine to perform the FPI of the HPC stage 3 to 8 drum, and that the 
average labor rate is $85 per work-hour. We also estimate that removal 
of silver residue from the engine would cost about $2,600 per engine. 
Required parts would cost about $795 per engine. We also estimate the 
cost of replacing a drum if found cracked would be $189,000. We have no 
way of determining the number of aircraft that might need this 
replacement. Based on these figures, we estimate the total cost of the 
proposed AD to U.S. operators to be $4,385,040.

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 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),
    (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 removing airworthiness directive 
(AD) 2010-20-07, Amendment 39-16441 (75 FR 59067, September 27, 2010), 
and adding the following new AD:

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

[[Page 82204]]

(a) Comments Due Date

    The FAA must receive comments on this AD action by February 28, 
2012.

(b) Affected ADs

    This AD supersedes AD 2010-20-07, Amendment 39-16441 (75 FR 
59067, September 27, 2010).

(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) 
up to and including V13181, and with S/Ns from V15000 up to and 
including V15245.

(d) Unsafe Condition

    This AD results from reports of 50 additional high-pressure 
compressor (HPC) stage 3 to 8 drums found cracked since AD 2010-20-
07 was issued. We are issuing this AD to prevent failure of the HPC 
stage 3 to 8 drum, uncontained engine failure, and damage to the 
airplane.

(e) Compliance

    You are responsible for having the actions required by this AD 
performed within the compliance times specified unless the actions 
have already been done.

(f) Initial Ultrasonic Inspections (USIs) of the HPC Stage 3 to 8 Drum

    (1) Using IAE Service Bulletin (SB) No. V2500-ENG-72-0615, 
Revision 3, dated September 20, 2011, Accomplishment Instructions, 
paragraph 3, perform an initial USI of the HPC stage 3 to 8 drum:
    (i) For IAE V2500-A1, V2522-A5, V2524-A5, V2527-A5, V2527E-A5, 
V2527M-A5, V2530-A5, and V2533-A5 turbofan engines with S/Ns in 
``Group A'' in Paragraph 1.A. in IAE SB No. V2500-ENG-72-0615, 
Revision 3, dated September 20, 2011, before accumulating 5,000 
cycles-since-new (CSN) or within 500 cycles from the effective date 
of this AD, whichever occurs later.
    (ii) For IAE V2500-A1, V2522-A5, V2524-A5, V2527-A5, V2527E-A5, 
V2527M-A5, V2530-A5, and V2533-A5 turbofan engines with S/Ns in 
``Group B'' in Paragraph 1.A. in IAE SB No. V2500-ENG-72-0615, 
Revision 3, dated September 20, 2011, before accumulating 12,500 CSN 
or within 500 cycles from the effective date of this AD, whichever 
occurs later, not to exceed 13,700 CSN.
    (2) For all IAE V2525-D5 and V2528-D5 turbofan engines, using 
IAE SB No. V2500-ENG-72-0608, Revision 3 dated September 20, 2011, 
Accomplishment Instructions, paragraph 3, perform an initial USI of 
the HPC stage 3 to 8 drum before accumulating 12,500 CSN or within 
500 cycles from the effective date of this AD, whichever occurs 
later, not to exceed 13,700 CSN.
    (3) If cracks or crack indications are identified, remove the 
drum from service before further flight.

(g) Removal of All Fully Silver Plated Nuts

    (1) At the next piece part exposure of the HPC stage 3 to 8 drum 
after the effective date of this AD, but no later than 8 years from 
the effective date of this AD, do the following before returning any 
HPC stage 3 to 8 drum to service:
    (i) Remove from service all fully silver plated nuts, part 
number (P/N) AS44862 or equivalent, that attach the HPC stage 3 to 8 
drum to the HPC stage 9 to 12 drum.
    (ii) Remove the silver residue from the HPC stage 3 to 8 drum 
using the IAE SB No. V2500-ENG-72-0601, Revision 2, dated April 12, 
2010, Accomplishment Instructions, paragraph 3. Drums cleaned before 
the effective date of this AD using engine manual task 72-41-11-110-
001 satisfy this requirement.
    (2) Perform an inspection using one of the following methods:
    (i) Fluorescent penetrant inspect (FPI) the HPC stage 3 to 8 
drum for cracks, and remove from service any drum found cracked. You 
can find guidance on performing an FPI of the HPC stage 3 to 8 drum 
in IAE engine manual task 72-41-11-200-001.
    (ii) Eddy Current Inspect (ECI) the HPC stage 3 to 8 drum for 
cracks, using IAE SB No. V2500-ENG-72-0625, dated September 20, 
2011, and remove from service any drum found cracked.
    (3) If cracks or crack indications are identified, remove the 
drum from service before further flight.

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

    Perform repetitive USIs of the HPC stage 3 to 8 drum for cracks 
in accordance with paragraphs (f)(1) or (f)(2) of this AD as 
follows:
    (1) Within every 750 cycles-since-last USI; or
    (2) Within 2,500 cycles-since-last FPI; or
    (3) Within 13,000 cycles-since-last ECI, whichever occurs 
latest.

(i) Optional Terminating Action

    Accomplishment of paragraphs (h)(1) and (h)(2) of this AD, 
eliminate the cleaning and inspection requirements of this AD and no 
further actions are required.
    (1) Remove from service all fully silver plated nuts, P/N 
AS44862 or equivalent, that attach the HPC stage 3 to 8 drum to the 
HPC stage 9 to 12 drum.
    (2) Install a zero-time HPC stage 3 to 8 drum or a drum that has 
never operated with fully silver plated nuts, P/N AS44862 or 
equivalent, that attach the HPC stage 3 to 8 drum to the HPC stage 9 
to 12 drum.

(j) Definitions

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

(k) Previous Credit

    (1) Initial or repetitive USIs of the HPC stage 3 to 8 drum 
using IAE SB No. V2500-ENG-72-0594, Revision 3, dated August 7, 
2009, or Revision 4, dated October 13, 2009, or Revision 5, dated 
November 23, 2009, or Revision 6, dated April 12, 2010, before the 
effective date of this AD, meets the inspection requirements of 
paragraphs (f)(1) through (f)(3) of this AD.
    (2) Initial or repetitive USIs of the HPC stage 3 to 8 drum 
using IAE SB No. V2500-ENG-72-0603, Original Issue, dated November 
24 2009, or Revision 1, dated December 18, 2009, or Revision 2, 
dated March 17, 2010, before the effective date of this AD, meets 
the inspection requirements of paragraphs (f)(1) through (f)(3) of 
this AD.
    (3) Initial or repetitive USIs of the HPC stage 3 to 8 drum 
using IAE SB No. V2500-ENG-72-0608, Revision 3, dated September 20, 
2011, before the effective date of this AD, meets the inspection 
requirements of paragraphs (f)(1) through (f)(3) of this AD.
    (4) Initial or repetitive USIs of the HPC stage 3 to 8 drum 
using IAE SB No. V2500-ENG-72-615, Revision 3, dated September 20, 
2011, before the effective date of this AD, meets the inspection 
requirements of paragraphs (f)(1) through (f)(3) of this AD.

(l) Alternative Methods of Compliance (AMOCs)

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

(m) Related Information

    (1) For more information about this AD, contact Carlos 
Fernandes, Aerospace Engineer, Engine Certification Office, FAA, 
Engine & Propeller Directorate, 12 New England Executive Park, 
Burlington, MA 01803; phone: (781) 238-7189; fax: (781) 238-7199; 
email: carlos.fernandes@faa.gov.
    (2) For service information identified in this AD, contact 
International Aero Engines AG, 628 Hebron Avenue, Suite 400, 
Glastonbury, CT 06033; phone: (860) 368-3700; fax: (860) 368-4600; 
email: iaeinfo@iaev2500.com; Web site: https://www.iaeworld.com.
    (3) You may review copies of the referenced 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 23, 2011.
Peter A. White,
Manager, Engine & Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 2011-33536 Filed 12-29-11; 8:45 am]
BILLING CODE 4910-13-P