Document ID: FAA-2009-0811-0008
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Rolls-Royce Corp. (RRC) AE 3007A Series Turbofan Engines
Posted Date: 2010-09-22T04:00Z

[Federal Register: September 22, 2010 (Volume 75, Number 183)]
[Rules and Regulations]               
[Page 57660-57664]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr22se10-4]                         

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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; 
Amendment 39-16429; AD 2010-19-01]
RIN 2120-AA64

 
Airworthiness Directives; Rolls-Royce Corporation (RRC) AE 3007A 
Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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

SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for RRC AE 3007A series turbofan engines. That AD currently 
requires performing an eddy current inspection (ECI) or surface wave 
ultrasonic test (SWUT) inspection on each affected high-pressure 
turbine (HPT) wheel. This AD requires removing or performing initial 
and repetitive ECIs or SWUT inspections on HPT stage 2 wheels for 
cracks. This AD also reduces the approved life limits of certain HPT 
stage 2 wheels. This AD results from reports of cracked HPT stage 2 
wheels. We are issuing this AD to prevent uncontained failure of the 
HPT stage 2 wheel and damage to the airplane.

DATES: This AD becomes effective October 27, 2010. The Director of the 
Federal Register approved the incorporation by reference of certain

[[Page 57661]]

publications listed in the regulations as of October 27, 2010.

ADDRESSES: You can get the service information identified in this AD 
from Rolls-Royce Corporation, P.O. Box 420, Speed Code U15, 
Indianapolis, IN 46206-0420, 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; e-mail: 
kyri.zaroyiannis@faa.gov; telephone (847) 294-7836; fax (847) 294-7834.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 by 
superseding AD 2009-08-51, Amendment 39-15905 (74 FR 22091, May 12, 
2009), with a proposed AD. The proposed AD applies to RRC AE 3007A 
series turbofan engines. We published the proposed AD in the Federal 
Register on February 18, 2010 (75 FR 7209). That action proposed to 
require:
     Removing from service, any engine with certain part number 
(P/N) HPT stage 2 wheels that have a cycles-since-new (CSN) specified 
in Table 1 of this AD, by the compliance time specified in Table 1 of 
this AD; or
     Performing an ECI or SWUT inspection on certain P/N HPT 
stage 2 wheels that have a CSN specified in Table 1 of this AD by the 
compliance time specified in Table 1 of this AD; and
     Performing repetitive ECI or SWUT inspections of the HPT 
stage 2 wheels within 3,000 cycles-since-last inspection.

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

Request To Clarify Repetitive Inspection Paragraph

    One commenter asks us to clarify paragraph (i) of the proposed AD, 
which states ``Thereafter, within 3,000 cycles since last inspection, 
remove the engine from service * * *'' The commenter asks if the last 
inspection means those inspections performed to comply with ADs 2008-
19-51, 2008-26-06 and 2009-08-51. The commenter feels paragraph (i) of 
the proposed AD is not clear.
    We agree. We changed paragraph (i) of this AD to ``Thereafter, 
within 3,000 cycles-since-last inspection performed as a result of this 
AD or its predecessor ADs (Emergency ADs 2008-19-51, AD 2008-26-06, and 
2009-08-51), remove the engine from service * * *

Request To Credit for Work Done to Previous Revisions of the Service 
Bulletins

    Four commenters ask us to allow credit for initial and repetitive 
inspections performed using previous versions of RRC Alert Service 
Bulletin (ASB) AE 3007A-A-72-367, Revision 2, dated June 22, 2009, 
Service Bulletin (SB) AE 3007A-72-176, Revision 5, dated September 2, 
2008; SB AE 3007A-72-215, Revision 2, dated September 28, 2009; SB AE 
3007A-72-368, Revision 3, dated May 24, 2010; and SB AE 3007A-72-369, 
Revision 2, dated November 5, 2009.
    We agree. We added paragraph (g)(6) to allow credit for initial and 
repetitive inspections performed using earlier versions of RRC ASB AE 
3007A-A-72-367, Revision 2, dated June 22, 2009; SB AE 3007A-72-368, 
Revision 3, dated May 24, 2010; and SB AE 3007A-72-369, Revision 2, 
dated November 5, 2009. We also changed paragraph (l) of this AD to 
state ``For wheels, P/N 23069438 * * * RRC SB AE 3007A-72-176, Revision 
5, dated September 2, 2008, or earlier version; or SB AE 3007A-72-215, 
Revision 2, dated September 28, 2009, or earlier version, remove the 
wheel before exceeding the new, reduced ECLL of 10,000 CSN.''

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 1402 engines installed on 
airplanes of U.S. registry. We also estimate that it will take about 2 
work-hours per engine to perform both the ECI and SWUT. The average 
labor rate is $85 per work-hour. No parts are required for the 
inspection. We estimate the prorated life lost per stage 2 wheel is 
about $13,177. Based on these figures, we estimate the total cost of 
the AD to U.S. operators to be $18,712,494. This estimate is exclusive 
of any warranty coverage.

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); 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.

[[Page 57662]]

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 39-15905 (74 FR 
22091, May 12, 2009), and by adding a new airworthiness directive, 
Amendment 39-16429, to read as follows:

2010-19-01 Rolls-Royce Corporation (Formerly Allison Engine 
Company): Amendment 39-16429. Docket No. FAA-2009-0811; Directorate 
Identifier 2008-NE-41-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective October 
27, 2010.

Affected ADs

    (b) This AD supersedes AD 2009-08-51, Amendment 39-15905.

Applicability

    (c) This AD applies to Rolls-Royce Corporation (RRC) AE 3007A 
series turbofan engines with high-pressure turbine (HPT) stage 2 
wheels, part numbers (P/Ns) 23069438, 23069592, 23074462, 23074644, 
23075345, or 23084520 installed. These engines are installed on, but 
not limited to, Empresa Brasileira de Aeronautica S. A. (EMBRAER) 
EMB-135 and EMB-145 airplanes.

Unsafe Condition

    (d) This AD results from reports of cracked HPT stage 2 wheels. 
We are issuing this AD to prevent uncontained failure of the HPT 
stage 2 wheel and damage to 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.

HPT Stage 2 Wheels Exempted From the Inspection Requirements of This AD

    (f) The following engines are exempt from the inspection 
requirements of this AD:
    (1) All engines with an HPT stage 2 wheel, P/N 23084520.
    (2) All engines with an HPT stage 2 wheel, P/N 23075345, that 
has a serial number (S/N) specified in Table 1 of this AD, and
    (3) All engines with an HPT stage 2 wheel, P/N 23074462, that 
has a S/N specified in Table 2 of this AD.

Table 1--HPT Stage 2 Wheel, P/N 23075345 by S/N Excluded From Inspection
                 Requirements (g) Through (i) of This AD
------------------------------------------------------------------------

------------------------------------------------------------------------
MM507646                 MM508211                 MM508319
MM508144                 MM508221                 MM508320
MM508153                 MM508241                 MM508322
MM508176                 MM508248                 MM508337
MM508186                 MM508251                 MM508338
MM508188                 MM508264                 MM508382
MM508205                 MM508305                 MM508387
MM508208                 MM508311                 ......................
------------------------------------------------------------------------

Table 2--HPT Stage 2 Wheel, P/N 23074462 by S/N Excluded From Inspection
                 Requirements (g) Through (i) of This AD
------------------------------------------------------------------------

------------------------------------------------------------------------
MM504890                 MM505025                 MM505054
MM504963                 MM505034                 MM505055
MM504990                 MM505041                 MM505056
MM504995                 MM505045                 MM505061
MM505007                 MM505046                 All `MM' prefix S/Ns
                                                   higher than MM505061
MM505017                 MM505048                 All S/Ns with `MW'
                                                   prefix
------------------------------------------------------------------------

Initial Eddy Current Inspection (ECI) or Surface Wave Ultrasonic 
Testing (SWUT) Inspection

    (g) For engines with an HPT stage 2 wheel, P/Ns 23069438, 
23069592, 23074462, 23074644, or 23075345, remove the engine from 
service or perform an initial inspection of the wheel by the cycle 
limit specified in Table 3 of this AD. Use one of the following 
methods for the inspection:
    (1) For HPT stage 2 wheels that have S/Ns listed in Table 4 of 
this AD, use paragraphs 2.A. through 2.C.(4) of RRC Alert Service 
Bulletin (ASB) AE 3007A-A-72-367, Revision 2 dated June 22, 2009, to 
inspect the wheel.
    (2) For HPT stage 2 wheels that have S/Ns not listed in Table 4 
of this AD, use paragraphs 2.A. through 2.C.(4) of RRC ASB AE 3007A-
A-72-367, Revision 2, dated June 22, 2009, or use paragraphs 2.A. 
through 2.N. of RRC Service Bulletin (SB) AE 3007A-72-368, Revision 
3, dated May 24, 2010; or use 2.A. through 2.V.(4) of RRC SB AE 
3007A-72-369, Revision 2, dated November 5, 2009, to perform the 
inspections.

 Table 3--Compliance Times for Engine Removal or ECI or SWUT Inspection
              of the HPT Stage 2 Wheels by Cycles-Since-New
                                  [CSN]
------------------------------------------------------------------------
                                          Remove engine from service or
    For HPT stage 2 wheels with the          inspect wheel within the
 following CSN on the effective date of    following cycles-in-service
                this AD:                  (CIS) after the effective date
                                                   of this AD:
------------------------------------------------------------------------
(3) 17,500 or more CSN.................  Remove engine from service or
                                          inspect before next flight.
(4) 10,000 to 17,499 CSN...............  15 CIS.
(5) 9,999 or fewer CSN.................  Before accumulating 10,015 CSN.
------------------------------------------------------------------------

Credit for Previous Inspections

    (6) Inspections performed before the effective date of this AD 
using earlier versions of RRC ASB AE 3007A-A-72-367 or RRC SB AE 
3007A-72-368 or RRC SB AE 3007A-72-369 comply with the requirements 
of paragraphs (g)(1) and (g)(2) of this AD.

 Table 4--S/Ns of HPT Stage 2 Wheels to be Inspected by SB AE 3007A-72-
                                   367
                            [ECI Method Only]
------------------------------------------------------------------------

------------------------------------------------------------------------
              HPT stage 2 wheels requiring ECI method only
------------------------------------------------------------------------
MM119400                             MM183796
MM119480                             MM183808
MM119508                             MM183831
MM155847                             MM228730
MM155907                             MM228951
MM155908                             MM503748
MM183236                             MM504004
MM183362                             MM57188
MM183754                             MM57440
MM183762                             MM57480
------------------------------------------------------------------------

Installation Prohibition

    (h) After the effective date of this AD, don't return to 
service, any HPT stage 2 wheel that was installed in any RRC AE 
3007A series engine that has been removed as a result of the 
inspection requirements of this AD, unless the HPT stage 2 wheel was 
inspected as specified in RRC ASB AE 3007A-A-72-367, Revision 2, 
dated June 22, 2009; or RRC

[[Page 57663]]

SB AE 3007A-72-368, Revision 3, dated May 24, 2010; or RRC SB AE 
3007A-72-369, Revision 2, dated November 5, 2009.

Repetitive Inspection

    (i) Thereafter, within 3,000 cycles-since-last inspection 
performed as a result of this AD or its predecessor ADs (Emergency 
ADs 2008-19-51, AD 2008-26-06, and 2009-08-51), remove the engine 
from service until an ECI or SWUT inspection is performed on the HPT 
stage 2 wheel. Use paragraphs 2.A. through 2.C.(4) of RRC ASB AE 
3007A-A-72-367, Revision 2, dated June 22, 2009, or use paragraphs 
2.A. through 2.N. of RRC SB AE 3007A-72-368, Revision 3, dated May 
24, 2010; or use 2.A. through 2.V.(4) of RRC SB AE 3007A-72-369, 
Revision 2, dated November 5, 2009, to inspect the wheel.

New, Reduced Engine Cycle Life Limit and Removal From Service

    (j) For HPT stage 2 wheels, P/N 23084520, do the following:
    (1) For wheels that have 22,985 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.
    (2) Thereafter, remove HPT stage 2 wheels, P/N 23084520, before 
exceeding the new, reduced engine cycle life limit (ECLL) of 23,000 
CSN.
    (k) For HPT stage 2 wheels, P/N 23075345 and 23074644, do the 
following:
    (1) For wheels that have 19,985 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 unless paragraph (k)(3) of this AD 
applies.
    (2) Thereafter, remove HPT stage 2 wheels, P/N 23075345 and 
23074644, before exceeding the new, reduced ECLL of 20,000 CSN.
    (3) For HPT stage 2 wheels, P/N 23075345, that have a S/N listed 
in Table 5 of this AD and that have 22,985 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.
    (4) Thereafter, for HPT stage 2 wheels, P/N 23075345, that have 
a S/N listed in Table 5 of this AD, remove the wheel from service 
before exceeding the new, reduced ECLL of 23,000 CSN.

 Table 5--S/Ns of HPT Stage 2 Wheel, P/N 23075345, Eligible To Remain in
                        Service Until 23,000 CSN
------------------------------------------------------------------------

------------------------------------------------------------------------
MM507646           MM508205           MM508251          MM508322
MM508144           MM508208           MM508264          MM508337
MM508153           MM508211           MM508305          MM508338
MM508176           MM508221           MM508311          MM508382
MM508186           MM508241           MM508319          MM508387
MM508188           MM508248           MM508320          ................
------------------------------------------------------------------------

     (l) For wheels, P/N 23069438, in engines that have not complied 
with RRC SB AE 3007A-72-176, Revision 5, dated September 2, 2008, or 
earlier version; or SB AE 3007A-72-215, Revision 2, dated September 
28, 2009, or earlier version, remove the wheel before exceeding the 
new, reduced ECLL of 10,000 CSN.
    (m) For wheels, P/N 23069438, in engines that have complied with 
RRC SB AE 3007A-72-176, Revision 5, dated September 2, 2008, or 
earlier version; or SB AE 3007A-72-215, Revision 2, dated September 
28, 2009, or earlier version; do the following:
    (1) For wheels that have 19,985 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.
    (2) Thereafter, remove the wheel from service before exceeding 
the new, reduced ECLL of 20,000 CSN.

Alternative Methods of Compliance

    (n) The Manager, Chicago Aircraft Certification Office, has the 
authority to approve alternative methods of compliance for this AD 
if requested using the procedures found in 14 CFR 39.19.

Special Flight Permits

    (o) Under 14 CFR 39.23, we are limiting the special flight 
permits for this AD by restricting the flight to essential flight 
crew only.

Related Information

    (p) 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

    (q) You must use the service information specified in Table 6 of 
this AD to perform the inspections required by this AD. The Director 
of the Federal Register approved the incorporation by reference of 
the documents listed in Table 6 of this AD in accordance with 5 
U.S.C. 552(a) and 1 CFR part 51. You can get a copy 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. 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 6--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
    Rolls-Royce Corporation Service
            Information No.                       Page             Revision                  Date
----------------------------------------------------------------------------------------------------------------
Alert Service Bulletin AE 3007A-A-72-   ALL.....................          2  June 22, 2009.
 367, Total Pages: 8.
Service Bulletin AE 3007A-72-368,       ALL.....................          3  May 24, 2010.
 Total Pages: 23.
Service Bulletin AE 3007A-72-369,       ALL.....................          2  November 5, 2009.
 Total Pages: 22.
----------------------------------------------------------------------------------------------------------------

[[Page 57664]]

    (Only the transmittal letter for Alert Service Bulletin (ASB) AE 
3007A-A-72-367, Revision 2, dated June 22, 2009, identifies this 
service bulletin as an ASB; no other page of this document contains 
this information.)

    Issued in Burlington, Massachusetts, on September 1, 2010.
Robert G. Mann,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2010-22370 Filed 9-21-10; 8:45 am]
BILLING CODE 4910-13-P