Proposed Rule2024-18354
Airworthiness Directives; Pratt & Whitney Engines
Primary source
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Published
August 19, 2024
Issuing agencies
Transportation DepartmentFederal Aviation Administration
Abstract
The FAA proposes to adopt a new airworthiness directive (AD) for certain Pratt & Whitney (PW) Model PW1519G, PW1521G, PW1521GA, PW1521G-3, PW1524G, PW1524G-3, PW1525G, PW1525G-3, PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A engines with a certain high-pressure compressor (HPC) 7th-stage axial rotor installed. This proposed AD was prompted by an analysis of an event involving an International Aero Engines, LLC (IAE LLC) Model PW1127GA-JM engine, which experienced an HPC 7th-stage integrally bladed rotor (IBR-7) separation that resulted in an aborted takeoff. This proposed AD would require performing initial and repetitive angled ultrasonic inspections (AUSI) of certain HPC 7th-stage axial rotors for cracks and replacing the HPC 7th-stage axial rotors if necessary. The FAA is proposing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 89 Issue 160 (Monday, August 19, 2024)</title>
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[Federal Register Volume 89, Number 160 (Monday, August 19, 2024)]
[Proposed Rules]
[Pages 67009-67012]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2024-18354]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2024-2026; Project Identifier AD-2024-00163-E]
RIN 2120-AA64
Airworthiness Directives; Pratt & Whitney 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 certain Pratt & Whitney (PW) Model PW1519G, PW1521G, PW1521GA,
PW1521G-3, PW1524G, PW1524G-3, PW1525G, PW1525G-3, PW1919G, PW1921G,
PW1922G, PW1923G, and PW1923G-A engines with a certain high-pressure
compressor (HPC) 7th-stage axial rotor installed. This proposed AD was
prompted by an analysis of an event involving an International Aero
Engines, LLC (IAE LLC) Model PW1127GA-JM engine, which experienced an
HPC 7th-stage integrally bladed rotor (IBR-7) separation that resulted
in an aborted takeoff. This proposed AD would require performing
initial and repetitive angled ultrasonic inspections (AUSI) of certain
HPC 7th-stage axial rotors for cracks and replacing the HPC 7th-stage
axial rotors if necessary. The FAA is proposing this AD to address the
unsafe condition on these products.
DATES: The FAA must receive comments on this proposed AD by October 3,
2024.
ADDRESSES: You may send comments, using the procedures found in 14 CFR
11.43 and 11.45, by any of the following methods:
<bullet> Federal eRulemaking Portal: Go to <a href="http://regulations.gov">regulations.gov</a>. Follow
the instructions for submitting comments.
<bullet> Fax: (202) 493-2251.
<bullet> 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.
<bullet> Hand Delivery: Deliver to Mail address above between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2024-2026; or in person at Docket Operations between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD
docket contains this NPRM, any comments received, and other
information. The street address for Docket Operations is listed above.
Material Incorporated by Reference:
<bullet> For PW material identified in this proposed AD, contact
Pratt & Whitney, 400 Main Street, East Hartford, CT 06118; phone: (860)
565-0140; email: <a href="/cdn-cgi/l/email-protection#a7cfc2cbd79593e7d7d5c6d3d3d0cfced3c9c2de89c4c8ca"><span class="__cf_email__" data-cfemail="a2cac7ced29096e2d2d0c3d6d6d5cacbd6ccc7db8cc1cdcf">[email protected]</span></a>; website:
<a href="http://connect.prattwhitney.com">connect.prattwhitney.com</a>.
<bullet> You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 1200 District Avenue,
Burlington, MA 01803. For information on the availability of this
material at the FAA, call (817) 222-5110.
FOR FURTHER INFORMATION CONTACT: Carol Nguyen, Aviation Safety
Engineer, FAA, 2200 South 216th Street, Des Moines, WA 98198; phone:
(781) 238-7655; email: <a href="/cdn-cgi/l/email-protection#c8aba9baa7a4e6a6afbdb1ada688aea9a9e6afa7be"><span class="__cf_email__" data-cfemail="debdbfacb1b2f0b0b9aba7bbb09eb8bfbff0b9b1a8">[email protected]</span></a>.
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites 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-2024-2026;
Project Identifier AD-2024-00163-E'' at the beginning of your comments.
The most helpful comments reference a specific portion of the proposal,
explain the reason for any recommended change, and include supporting
data. The FAA will consider all comments received by the closing date
and may revise this proposal because of those comments.
Except for Confidential Business Information (CBI) as described in
the following paragraph, and other information as described in 14 CFR
11.35, the FAA will post all comments received, without change, to
<a href="http://regulations.gov">regulations.gov</a>, including any personal information you provide. The
agency will also post a report summarizing each substantive verbal
contact received about this NPRM.
[[Page 67010]]
Confidential Business Information
CBI is commercial or financial information that is both customarily
and actually treated as private by its owner. Under the Freedom of
Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public
disclosure. If your comments responsive to this NPRM contain commercial
or financial information that is customarily treated as private, that
you actually treat as private, and that is relevant or responsive to
this NPRM, it is important that you clearly designate the submitted
comments as CBI. Please mark each page of your submission containing
CBI as ``PROPIN.'' The FAA will treat such marked submissions as
confidential under the FOIA, and they will not be placed in the public
docket of this NPRM. Submissions containing CBI should be sent to Carol
Nguyen, Aviation Safety Engineer, FAA, 2200 South 216th Street, Des
Moines, WA 98198. Any commentary that the FAA receives which is not
specifically designated as CBI will be placed in the public docket for
this rulemaking.
Background
On December 24, 2022, an Airbus Model A320neo airplane powered by
IAE LLC Model PW1127GA-JM engines, experienced a failure of the HPC
IBR-7 that resulted in an engine shutdown and aborted take-off.
Following this event, the manufacturer conducted a records review of
production and field-returned parts and re-evaluated their engineering
analysis methodology. The new analysis found that the failure of the
HPC IBR-7 was caused by a nickel powdered metal anomaly, similar in
nature to an anomaly previously observed, and these parts are
susceptible to failure much earlier than previously determined. As a
result, the FAA issued multiple ADs requiring AUSIs for certain
affected parts, however the overall mitigation plan included several
actions that were not available when those ADs were published. Since
that time, PW has developed the AUSI for the HPC 7th-stage axial
rotors. This condition, if not addressed, could result in uncontained
HPC 7th-stage axial rotor failure, release of high-energy debris,
damage to the engine, damage to the airplane, and possible loss of the
airplane.
FAA's Determination
The FAA is issuing this NPRM after determining that the unsafe
condition described previously is likely to exist or develop on other
products of the same type design.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed the following material:
<bullet> PW Alert Service Bulletin (ASB) PW1000G-A-72-00-0157-00A-
930A-D, Issue No: 002, dated May 22, 2024; and PW ASB PW1000G-A-72-00-
0210-00A-930A-D, Issue No: 002, dated May 22, 2024; which specify
procedures for performing initial AUSIs on affected HPC 7th-stage axial
rotors. This material also includes the serial numbers of affected HPC
7th-stage axial rotors. This material is distinct because it applies to
different engine models in different configurations.
<bullet> PW ASB PW1000G-A-72-00-0158-00B-930A-D, Issue No: 002,
dated August 1, 2024; and PW ASB PW1000G-A-72-00-0211-00A-930A-D, Issue
No: 002, dated August 1, 2024; which specify procedures for performing
repetitive AUSIs on affected HPC 7th-stage axial rotors. This material
is distinct because it applies to different engine models in different
configurations.
This material is reasonably available because the interested
parties have access to it through their normal course of business or by
the means identified in ADDRESSES.
Proposed AD Requirements in This NPRM
This proposed AD would require performing initial and repetitive
AUSIs of certain HPC 7th-stage axial rotors for cracks and replacement
if necessary.
Interim Action
The FAA considers this AD to be an interim action. This unsafe
condition is still under investigation by the manufacturer and,
depending on the results of that investigation, the FAA may consider
further rulemaking action.
Costs of Compliance
The FAA estimates that this AD, if adopted as proposed, would
affect 121 engines installed on airplanes of U.S. registry.
The FAA estimates the following costs to comply with this proposed
AD:
Estimated Costs
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Cost per Cost on U.S.
Action Labor cost Parts cost product operators
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AUSI of HPC 7th-stage axial rotor... 20 work-hours x $85 per $0 $1,700 $205,700
hour = $1,700.
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The FAA estimates the following costs to do any necessary
replacements that would be required based on the results of the
proposed inspection. The agency has no way of determining the number of
engines that might need these replacements:
On-Condition Costs
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Cost per
Action Labor cost Parts cost product
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Replacement of HPC 7th-stage axial rotor..... 1 work-hours x $85 per hour = $84,640 $84,725
$85.
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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.
The FAA is 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.
[[Page 67011]]
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
The FAA 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) Would not affect intrastate aviation in Alaska, 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.
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 adding the following new airworthiness
directive:
Pratt & Whitney: Docket No. FAA-2024-2026; Project Identifier AD-
2024-00163-E.
(a) Comments Due Date
The FAA must receive comments on this airworthiness directive
(AD) by October 3, 2024.
(b) Affected ADs
None.
(c) Applicability
This AD applies to Pratt & Whitney (PW) Model PW1519G, PW1521G,
PW1521GA, PW1521G-3, PW1524G, PW1524G-3, PW1525G, PW1525G-3,
PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A engines with an
installed high-pressure compressor (HPC) 7th-stage axial rotor
having part number (P/N) 30G5307.
(d) Subject
Joint Aircraft System Component (JASC) Code 7230, Turbine Engine
Compressor Section.
(e) Unsafe Condition
This AD was prompted by an analysis of an event involving an
International Aero Engines, LLC Model PW1127GA-JM engine, which
experienced an HPC 7th-stage integrally bladed rotor separation that
resulted in an aborted takeoff. The FAA is issuing this AD to
prevent failure of the HPC 7th-stage axial rotor. The unsafe
condition, if not addressed, could result in uncontained HPC 7th-
stage axial rotor failure, release of high-energy debris, damage to
the engine, damage to the airplane, and possible loss of the
airplane.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Required Actions
(1) At the next piece-part exposure after the effective date of
this AD and thereafter at each piece-part exposure, except as
required by paragraph (g)(2) and (4) of this AD, perform an angled
ultrasonic inspection (AUSI) of the affected HPC 7th-stage axial
rotor for cracks in accordance with paragraphs (g)(1)(i) and(ii) of
this AD, as applicable.
(i) For Model PW1500G engines: Step 7 of the Accomplishment
Instructions of PW Alert Service Bulletin (ASB) PW1000G-A-72-00-
0210-00A-930A-D, Issue No: 002, dated May 22, 2024 (PW1000G-A-72-00-
0210-00A-930A-D, Issue No: 002), or step 5.B of the Accomplishment
Instructions of PW ASB PW1000G-A-72-00-0211-00A-930A-D, Issue No:
002, dated August 1, 2024.
(ii) For Model PW1900G engines: Step 7 of the Accomplishment
Instructions of PW ASB PW1000G-A-72-00-0157-00A-930A-D, Issue No:
002, dated May 22, 2024 (PW1000G-A-72-00-0157-00A-930A-D, Issue No:
002), or step 5.B of the Accomplishment Instructions of PW ASB
PW1000G-A-72-00-0158-00B-930A-D, Issue No: 002, dated August 1,
2024.
(2) For engines with an installed HPC 7th-stage axial rotor and
a serial number listed in Table 1 of PW1000G-A-72-00-0210-00A-930A-
D, Issue No: 002, or Table 1 of PW1000G-A-72-00-0157-00A-930A-D,
Issue No: 002, that have not had an AUSI performed prior to the
effective date of this AD, at the next HPC engine shop visit after
the effective date of this AD, not to exceed 10,000 part cycles
since new, or within 100 flight cycles (FCs) after the effective
date of this AD, whichever occurs later, and thereafter at each
piece-part exposure: perform an AUSI of the HPC 7th-stage axial
rotor for cracks in accordance with paragraphs (g)(1)(i) and (ii) of
this AD, as applicable.
(3) If any crack is found during any inspection required by
paragraphs (g)(1) or (2) of this AD, before further flight, remove
the HPC 7th-stage axial rotor from service and replace with a part
eligible for installation.
(4) If an HPC 7th-stage axial rotor has accumulated 100 FCs or
less since the last AUSI, reinspection is not required provided that
the part was not damaged during removal from the engine.
(h) Definitions
For the purposes of this AD:
(1) ``Model PW1500G'' engines are PW Model PW1519G, PW1521G,
PW1521GA, PW1521G-3, PW1524G, PW1524G-3, PW1525G, and PW1525G-3
engines.
(2) ``Model PW1900G'' engines are PW Model PW1919G, PW1921G,
PW1922G, PW1923G, and PW1923G-A engines.
(3) A ``part eligible for installation'' is any of the
following:
(i) An HPC 7th-stage axial rotor, P/N 30G5307, that has passed
the AUSI required by paragraphs (g)(1) or (g)(2) of this AD.
(ii) An HPC 7th-stage axial rotor, P/N 30G5307, that has a
Certificate of Conformance that shows compliance with NDIP-1281.
(iii) An HPC 7th-stage axial rotor that has a later approved P/
N.
(4) A ``piece-part exposure'' is when the HPC 7th-stage axial
rotor is disassembled from the rotor assembly.
(5) An ``HPC engine shop visit'' is when the HPC rotor assembly
is removed from the HPC module.
(i) Credit for Previous Actions
This paragraph provides credit for the initial AUSI required by
paragraphs (g)(1) and (2) of this AD, if those actions were done
before the effective date of this AD using any of the following:
(1) PW ASB PW1000G-A-72-00-0157-00A-930A-D, Issue No: 001, dated
February 15, 2024.
(2) PW ASB PW1000G-A-72-00-0158-00B-930A-D, Issue No: 001, dated
February 19, 2024.
(3) PW ASB PW1000G-A-72-00-0210-00A-930A-D, Issue No: 001, dated
February 15, 2024.
(4) PW ASB PW1000G-A-72-00-0211-00A-930A-D, Issue No: 001, dated
February 19, 2024.
(j) Alternative Methods of Compliance (AMOCs)
(1) The Manager, AIR-520 Continued Operational Safety Branch,
FAA, has the authority to approve AMOCs for this AD, if requested
using the procedures found in 14 CFR 39.19. In accordance with 14
CFR 39.19, send your request to your principal inspector or local
Flight Standards District Office, as appropriate. If sending
information directly to the manager of AIR-520 Continued Operational
Safety Branch, send it to the attention of the person identified in
paragraph (k) of this AD and email to: <a href="/cdn-cgi/l/email-protection#d3929e9c9093b5b2b2fdb4bca5"><span class="__cf_email__" data-cfemail="0d4c40424e4d6b6c6c236a627b">[email protected]</span></a>.
(2) Before using any approved AMOC, notify your appropriate
principal inspector, or lacking a principal inspector, the manager
of the local flight standards district office/certificate holding
district office.
(k) Additional Information
For more information about this AD, contact Carol Nguyen,
Aviation Safety Engineer, FAA, 2200 South 216th Street, Des
[[Page 67012]]
Moines, WA 98198; phone: (781) 238-7655; email:
<a href="/cdn-cgi/l/email-protection#4e2d2f3c21226020293b372b200e282f2f60292138"><span class="__cf_email__" data-cfemail="46252734292a682821333f23280620272768212930">[email protected]</span></a>.
(l) Material Incorporated by Reference
(1) The Director of the Federal Register approved the
incorporation by reference (IBR) of the material listed in this
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
(2) You must use this material as applicable to do the actions
required by this AD, unless the AD specifies otherwise.
(i) Pratt & Whitney (PW) Alert Service Bulletin (ASB) PW1000G-A-
72-00-0157-00A-930A-D, Issue No: 002, dated May 22, 2024.
(ii) PW ASB PW1000G-A-72-00-0158-00B-930A-D, Issue No: 002,
dated August 1, 2024.
(iii) PW ASB PW1000G-A-72-00-0210-00A-930A-D, Issue No: 002,
dated May 22, 2024.
(iv) PW ASB PW1000G-A-72-00-0211-00A-930A-D, Issue No: 002,
dated August 1, 2024.
(3) For PW material identified in this AD, contact Pratt &
Whitney, 400 Main Street, East Hartford, CT 06118; phone: (860) 565-
0140; email: <a href="/cdn-cgi/l/email-protection#e58d808995d7d1a59597849191928d8c918b809ccb868a88"><span class="__cf_email__" data-cfemail="b1d9d4ddc18385f1c1c3d0c5c5c6d9d8c5dfd4c89fd2dedc">[email protected]</span></a>; website:
<a href="http://connect.prattwhitney.com">connect.prattwhitney.com</a>.
(4) You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 1200 District Avenue,
Burlington, MA 01803. For information on the availability of this
material at the FAA, call (817) 222-5110.
(5) You may view this material at the National Archives and
Records Administration (NARA). For information on the availability
of this material at NARA, visit <a href="http://www.archives.gov/federal-register/cfr/ibr-locations">www.archives.gov/federal-register/cfr/ibr-locations</a> or email <a href="/cdn-cgi/l/email-protection#fb9d89d59295888b9e988f929495bb959a899ad59c948d"><span class="__cf_email__" data-cfemail="2543570b4c4b56554046514c4a4b654b4457440b424a53">[email protected]</span></a>.
Issued on August 12, 2024.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft
Certification Service.
[FR Doc. 2024-18354 Filed 8-16-24; 8:45 am]
BILLING CODE 4910-13-P
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