Document ID: FAA-2009-1100-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: International Aero Engines AG (IAE) V2500-A1, V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, et al. Turbofan Engines
Posted Date: 2010-02-17T05:00Z

[Federal Register: February 12, 2010 (Volume 75, Number 29)]
[Proposed Rules]               
[Page 6860-6862]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr12fe10-10]                         

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Proposed Rules
                                                Federal Register
________________________________________________________________________

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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[[Page 6860]]

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0544; Directorate Identifier 2009-NE-37-AD]
RIN 2120-AA64

 
Airworthiness Directives; International Aero Engines AG (IAE) 
V2500-A1, V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, 
V2528-D5, V2530-A5, and V2533-A5 Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new 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. For certain S/Ns of V2500-A1, V2522-A5, 
V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 series 
turbofan engines, this proposed AD would require initial and repetitive 
on-wing ultrasonic inspections (UIs) of the high-pressure compressor 
(HPC) stage 3 to 8 drum for cracks. As mandatory terminating action to 
the repetitive inspections, this proposed AD would require 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 fluorescent penetrant inspection (FPI) of 
the stage 3 to 8 drum within a specified time. For all other engines, 
this proposed AD would require 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. 
This proposed AD results from reports of 39 HPC stage 3 to 8 drums 
found cracked since March 2009. We are proposing this AD to prevent 
uncontained failure of the HPC stage 3 to 8 drum, which could result in 
damage to the airplane.

DATES: We must receive any comments on this proposed AD by April 13, 
2010.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     Federal eRulemaking Portal: Go to http://
www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 1200 New Jersey Avenue, SE., West Building Ground 
Floor, Room W12-140, Washington, DC 20590-0001.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
     Fax: (202) 493-2251.
    Contact International Aero Engines AG, 400 Main Street, East 
Hartford, CT 06108; telephone: (860) 565-5515; fax: (860) 565-5510, for 
a copy of the service information identified in this proposed AD.

FOR FURTHER INFORMATION CONTACT: Kevin Dickert, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803; e-mail: 
kevin.dickert@faa.gov; telephone (781) 238-7117, fax (781) 238-7199.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2009-0544; Directorate 
Identifier 2009-NE-37-AD'' in the subject line of your comments. We 
specifically invite comments on the overall regulatory, economic, 
environmental, and energy aspects of the proposed AD. We will consider 
all comments received by the closing date and may amend the proposed AD 
in light 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 
with FAA personnel concerning this proposed AD. Using the search 
function of the Web site, anyone can find and read the comments in any 
of our dockets, including, if provided, the name of the individual who 
sent the comment (or signed the comment on behalf of an association, 
business, labor union, etc.). You may review the DOT's complete Privacy 
Act Statement in the Federal Register published on April 11, 2000 (65 
FR 19477-78).

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 proposed AD, the regulatory 
evaluation, any comments received, and other information. The street 
address for the Docket Operations office (telephone (800) 647-5527) is 
the same as the Mail address provided in the ADDRESSES section. 
Comments will be available in the AD docket shortly after receipt.

Discussion

    Since March 2009, we received reports of 12 V2500-A5 series HPC 
stage 3 to 8 drums found cracked during shop visit inspections, and 
reports of 24 V2500-A5 series HPC stage 3 to 8 drums found cracked 
during on-wing inspections. We also received reports of 3 V2500-A1 
stage 3 to 8 drums found cracked during shop visits. Analysis revealed 
that high levels of chlorine in the engine, combined with engine 
operation in high temperature and high humidity environments, led to 
depletion of the silver plating on the exterior of the nuts that attach 
the HPC stage 3 to 8 drum to the HPC stage 9 to 12 drum. The depletion 
of the silver plating led to deposits of silver chloride on the HPC 
stage 3 to 8 drum, causing stress corrosion and cracking. This 
condition, if not corrected, could result in uncontained failure of the 
HPC stage 3 to 8 drum, which could result in damage to the airplane.

Relevant Service Information

    We have reviewed and approved the technical contents of IAE Service 
Bulletin (SB) No. V2500-ENG-72-0594,

[[Page 6861]]

Revision 5, dated November 23, 2009, and IAE SB No. V2500-ENG-0603, 
Revision 1, dated December 18, 2009, which describe procedures for 
performing initial and repetitive on-wing UIs of HPC stage 3 to 8 drums 
for cracks. We have also reviewed and approved the technical contents 
of IAE SB No. V2500-ENG-72-0601, Revision 1, dated December 18, 2009, 
which describes procedures for removal of silver residue from the HPC 
stage 3 to 8 drum. Although SB No. V2500-ENG-72-0601, Revision 1, dated 
December 18, 2009, only specifies certain S/N engines in the 
effectivity section, we are proposing to require accomplishing this 
bulletin on all engines affected by this AD.
    V2500-A5 series engines with S/Ns listed in Groups ``A'' and ``D'' 
of IAE SB No. V2500-ENG-72-0594, Revision 5, dated November 23, 2009, 
and V2500-A1 series engines with S/Ns listed in ``Group A'' of IAE SB 
No. V2500-ENG-72-0603, Revision 1, dated December 18, 2009, are those 
engines suspect of having been exposed to excessive levels of chlorine 
contamination. These engines require initial and repetitive inspection 
of the HPC stage 3 to 8 drum for cracks, and removal from service of 
the fully silver plated nuts joining the HPC stage 3 to 8 drum to the 
HPC stage 9 to 12 drum within 27 months from the effective date of the 
proposed AD.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design. We are proposing this AD, which would 
require:

 For certain S/Ns of IAE V2500-A1, V2522-A5, V2524-A5, V2527-
A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 turbofan engines:
    [cir] Initial and repetitive on-wing UIs of HPC stage 3 to 8 drums 
for cracks; and
    [cir] As mandatory terminating action to the repetitive UIs, within 
27 months from the effective date of this AD, 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 drums, and FPI of the HPC stage 3 to 8 drums.
 For all other engines, at the next piece-part exposure of the 
HPC stage 3 to 8 drum, 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 drums, and FPI of 
the HPC stage 3 to 8 drums.

The proposed AD would require you to use the service information 
described previously to perform the inspections and removal of silver 
residue.

Costs of Compliance

    We estimate that this proposed AD would affect 848 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 29 of these engines would require UIs, and 
that it would take about 3 work-hours per engine to perform one UI. 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. Based on these figures, we estimate 
the total cost of the proposed AD to U.S. operators to be $3,030,515.

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 AD:
    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); and
    3. Would 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 regulatory evaluation of the estimated costs to 
comply with this proposed AD. 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.

The Proposed Amendment

    Under the authority delegated to me by the Administrator, the 
Federal Aviation Administration 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:

International Aero Engines AG: Docket No. FAA-2009-0544; Directorate 
Identifier 2009-NE-37-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by April 13, 
2010.

Affected ADs

    (b) None.

Applicability

    (c) 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.
    (4) These engines are installed on, but not limited to, Airbus 
A319, A320, and A321, and McDonnell Douglas MD-90 airplanes.

Unsafe Condition

    (d) This AD results from reports of 39 high-pressure compressor 
(HPC) stage 3 to 8 drums found cracked since March 2009. We

[[Page 6862]]

are issuing this AD to prevent uncontained failure of the HPC stage 
3 to 8 drum, which could result in 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.

Engines Requiring Ultrasonic Inspections (UI) of the HPC Stage 3 to 8 
Drum

    (f) For IAE V2522-A5, V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, 
V2530-A5, and V2533-A5 turbofan engines with S/Ns in ``Group A'' or 
``Group D'' in IAE Service Bulletin (SB) No. V2500-ENG-72-0594, 
Revision 5, dated November 23, 2009, and for V2500-A1 turbofan 
engines with S/Ns in ``Group A'' in IAE SB No. V2500-ENG-72-0603, 
Revision 1, dated December 18, 2009, do the following:
    (1) Perform an initial UI of the HPC stage 3 to 8 drum using 
paragraph 3 of the Accomplishment Instructions of IAE SB No. V2500-
ENG-72-0594, Revision 5, dated November 23, 2009, or IAE SB No. 
V2500-ENG-72-0603, Revision 1, dated December 18, 2009, as 
applicable, before accumulating 5,200 cycles-since-new (CSN) or 
within 500 cycles from the effective date of this AD, whichever 
occurs later.
    (2) Thereafter, perform repetitive UIs of the HPC stage 3 to 8 
drum for cracks within every 500 cycles-since-last-inspection.
    (3) If cracks or crack indications are identified, remove the 
drum from service before further flight.

Mandatory Terminating Action

    (4) As mandatory terminating action to the repetitive 
inspections required by this AD, at the next engine shop visit, but 
no later than 27 months after the effective date of this AD, do the 
following before returning any HPC stage 8 to 12 drum to service:
    (i) Remove from service 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 paragraph 3 of the Accomplishment Instructions of IAE SB No. 
V2500-ENG-72-0601, Revision 1, dated December 18, 2009. Drums 
cleaned before the effective date of this AD using engine manual 
task 72-41-11-110-001 satisfy this requirement.
    (iii) 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.
    (iv) Installation of 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 eliminates the need for the cleaning and FPI 
required by paragraphs (f)(4)(ii) and (f)(4)(iii) of this AD.

All Other Engines

    (g) For all other engines, 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 the drum to service:
    (1) Remove from service 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) Remove the silver residue from the HPC stage 3 to 8 drum 
using paragraph 3 of the Accomplishment Instructions of IAE SB No. 
V2500-ENG-72-0601, Revision 1, dated December 18, 2009. Drums 
cleaned before the effective date of this AD using engine manual 
task 72-41-11-110-001 satisfy this requirement.
    (3) 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.
    (4) Installation of 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 eliminates the need for the cleaning and FPI 
required by paragraphs (g)(2) and (g)(3) of this AD.

Definitions

    (h) For the purpose of this AD, an engine shop visit is the 
induction of an engine into the shop for maintenance involving the 
separation of a pair of major mating engine flanges, except that the 
separation of engine flanges solely for the purposes of 
transportation without subsequent engine maintenance does not 
constitute an engine shop visit.
    (i) For the purpose of this AD, piece-part exposure of the HPC 
stage 3 to 8 drum is removal of the drum from the engine and removal 
of all blades from the drum.

Previous Credit

    (j) Initial or repetitive ultrasonic inspections 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, before 
the effective date of this AD, meets the inspection requirements of 
paragraphs (f)(1) through (f)(3) of this AD.
    (k) Initial or repetitive ultrasonic inspections of the HPC 
stage 3 to 8 drum using IAE SB No. V2500-ENG-72-0603, Original 
Issue, dated November 24, 2009, before the effective date of this 
AD, meets the inspection requirements of paragraphs (f)(1) through 
(f)(3) of this AD.

Alternative Methods of Compliance

    (l) The Manager, Engine 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.

Related Information

    (m) Contact Kevin Dickert, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; e-mail: 
kevin.dickert@faa.gov; telephone (781) 238-7117, fax (781) 238-7199, 
for more information about this AD.
    (n) Contact International Aero Engines AG, 400 Main Street, East 
Hartford, CT 06108; telephone: (860) 565-5515; fax: (860) 565-5510, 
for a copy of the service information referenced in this AD.

    Issued in Burlington, Massachusetts, on February 8, 2010.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2010-2999 Filed 2-11-10; 8:45 am]
BILLING CODE 4910-13-P