81 FR 23581 - Airworthiness Directives; The Boeing Company Airplanes

DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration

Federal Register Volume 81, Issue 78 (April 22, 2016)

We are adopting a new airworthiness directive (AD) for The Boeing Company Model 787-8 and 787-9 airplanes powered by General Electric (GE) GEnx-1B engines. This AD requires revising the airplane flight manual (AFM) to provide the flight crew a revised fan ice removal procedure and a new associated mandatory flight crew briefing to reduce the likelihood of engine damage due to fan ice shedding. This AD also removes certain dispatch relief. For airplanes with certain engines, this AD also requires reworking or replacing at least one engine. This AD was prompted by a recent engine fan blade rub event that caused an in-flight non-restartable power loss. We are issuing this AD to prevent susceptibility to heavy fan blade rubs, which could result in engine damage and a possible in-flight non-restartable power loss of one or both engines.

[Federal Register Volume 81, Number 78 (Friday, April 22, 2016)]
[Rules and Regulations]
[Pages 23581-23586]
From the Federal Register Online  [www.thefederalregister.org]
[FR Doc No: 2016-09000]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2016-5592; Directorate Identifier 2016-NM-040-AD; 
Amendment 39-18488; AD 2016-08-12]
RIN 2120-AA64


Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: We are adopting a new airworthiness directive (AD) for The 
Boeing Company Model 787-8 and 787-9 airplanes powered by General 
Electric (GE) GEnx-1B engines. This AD requires revising the airplane 
flight manual (AFM) to provide the flight crew a revised fan ice 
removal procedure and a new associated mandatory flight crew briefing 
to reduce the likelihood of engine damage due to fan ice shedding. This 
AD also removes certain dispatch relief. For airplanes with certain 
engines, this AD also requires reworking or replacing at least one 
engine. This AD was prompted by a recent engine fan blade rub event 
that caused an in-flight non-restartable power loss. We are issuing 
this AD to prevent susceptibility to heavy fan blade rubs, which could 
result in engine damage and a possible in-flight non-restartable power 
loss of one or both engines.

DATES: This AD is effective May 9, 2016.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of May 9, 2016.
    The Director of the Federal Register approved the incorporation by 
reference of a certain other publication listed in this AD as of March 
18, 2016 (81 FR 14704, March 18, 2016).
    We must receive comments on this AD by June 6, 2016.

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: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    For service information identified in this final rule, contact 
General Electric Company, GE Aviation, Room 285, 1 Neumann Way, 
Cincinnati, OH 45215; phone: 513-552-3272; email: 
[email protected]. You may view this referenced service 
information at the FAA, Transport Airplane Directorate, 1601 Lind 
Avenue SW., Renton, WA. For information on the availability of this 
material at the FAA, call 425-227-1221. It is also available on the 
Internet at http://www.regulations.gov by searching for and locating 
Docket No. FAA-2016-5592.

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-2016-
5592; 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 AD, the regulatory evaluation, any comments received, and

[[Page 23582]]

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: Sue Lucier, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification Office 
(ACO), 1601 Lind Avenue SW., Renton, WA 98057-3356; phone: 425-917-
6438; fax: 425-917-6590; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    On March 14, 2016, we issued AD 2016-06-08, Amendment 39-18439 (81 
FR 14704, March 18, 2016) (``AD 2016-06-08''), for Boeing Model 787-8 
and 787-9 airplanes powered by GE GEnx engines. AD 2016-06-08 was 
prompted by a report of a significant fan rub event involving a GEnx-1B 
Performance Improvement Program (PIP) 2 engine, apparently caused by 
partial fan ice shedding and a resulting fan imbalance that in turn 
caused substantial damage to the engine and an in-flight non-
restartable power loss. GEnx-1B PIP1 engines have model designators 
GEnx-1B( )/P1. GEnx-1B PIP2 engines have model designators GEnx-1B( )/
P2.
    We continue to investigate this issue with Boeing and GE; however, 
the engine damage appears to be a result of susceptibility to heavy fan 
blade rubs common to the GEnx-1B PIP2 engine. The other engine on the 
event airplane was an older design GEnx-1B PIP1 configuration that 
incurred expected wear and minor damage during the icing event and 
continued to operate normally. The event occurred in icing conditions 
at an altitude of 20,000 feet.
    The urgency of this issue stems from the safety concern over 
continued safe flight and landing for airplanes that are powered by two 
GEnx-1B PIP2 engines operating in a similar environment to the event 
airplane. In this case both GEnx-1B PIP2 engines may be similarly 
damaged and unable to be restarted in flight. The potential for common 
cause failure of both engines in flight is an urgent safety issue.
    AD 2016-06-08 requires revising the airplane flight manual (AFM) to 
provide the flight crew a new fan ice removal procedure to reduce the 
likelihood of engine damage due to fan ice shedding. AD 2016-06-08 also 
requires, for certain airplanes, reworking the fan stator module 
assembly on GEnx-1B PIP2 engines.
    Susceptibility to heavy fan blade rubs, if not corrected, could 
result in engine damage and a possible in-flight non-restartable power 
loss of one or both engines. We are issuing this AD to correct the 
unsafe condition on these products.
    The preamble to AD 2016-06-08 explains that we regard the 
requirements ``interim action'' and were considering further 
rulemaking. We now have determined that further rulemaking is indeed 
necessary, and this AD follows from that determination.

Related Service Information Under 1 CFR Part 51

    We reviewed GE GEnx-1B Service Bulletins 72-0309 R00, dated March 
11, 2016; and 72-0314 R00, dated April 1, 2016. The service information 
describes procedures for reworking the fan stator module assembly on 
GEnx-1B PIP2 engines. This service information is reasonably available 
because the interested parties have access to it through their normal 
course of business or by the means identified in the ADDRESSES section.

FAA's Determination

    We are issuing 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.

AD Requirements

    This AD requires revising the AFM to provide the flight crew a 
revised fan ice removal procedure and a new associated mandatory flight 
crew briefing to reduce the likelihood of engine damage due to fan ice 
shedding. This AD also removes certain dispatch relief. For an airplane 
with two GEnx-1B PIP2 engines having specified model and part numbers, 
this AD also requires reworking or replacing at least one engine.

Interim Action

    We consider this AD interim action. This action addresses rework of 
a single engine on any airplane that has two GEnx-1B PIP2 engines 
having certain model and part numbers. We may consider issuing further 
rulemaking to require rework of the remainder of the GEnx-1B PIP2 
engines in this fleet.

FAA's Justification and Determination of the Effective Date

    An unsafe condition exists that requires the immediate adoption of 
this AD. The FAA has found that the risk to the flying public justifies 
waiving notice and comment prior to adoption of this rule because 
susceptibility to heavy fan blade rubs could result in engine damage 
and a possible in-flight non-restartable power loss of one or both 
engines. Therefore, we find that notice and opportunity for prior 
public comment are impracticable and that good cause exists for making 
this amendment effective in less than 30 days.

Explanation of Compliance Times

    The FAA has evaluated the safety risk associated with this 
condition and has determined that in the interest of safety it is 
necessary to mandate three actions:
     Revise the Boeing Model 787 AFM to provide the flight crew 
a revised fan ice removal procedure and a new daily flight crew 
briefing on the existing engine ice shed procedure. The compliance time 
is 7 days.
     Removes certain dispatch relief, effective within 7 days.
     Rework or replacement of at least one engine, for 
airplanes with two GEnx-1B PIP2 engines. The compliance time is about 
150 calendar days after issuance of this AD. Boeing and the engine 
manufacturer, GE, have developed a maintenance plan to support this 
compliance schedule.
    The FAA has determined that allowing for notice and public comment 
through a notice of proposed rulemaking (NPRM) prior to mandating these 
actions is neither practicable nor in the public interest.
    Recognizing the urgency of this safety issue, this AD represents a 
compressed schedule to rework a large number of airplanes located 
around the world. Both specialized tooling and trained personnel are 
required on-site to perform the rework at various maintenance 
facilities around the world. To complete the work, 29 airlines will 
need to reallocate 176 airplanes from revenue service to maintenance in 
order to conduct the (on-wing) rework. The FAA has determined that 150 
days is the minimum time to rework one engine per airplane on the 
entire fleet.
    Issuing an NPRM would require time to allow for public comment, and 
time for the FAA to consider and respond to those comments. As a 
result, the time allowed for the operators to perform the engine rework 
would be significantly reduced from 150 days, owing to the time that 
elapsed during the notice and comment period.
    As a result, the considerable reduction in allowable compliance 
time would require operators to perform the rework significantly out of 
sequence with the maintenance schedule plan. In some cases, airplanes 
could be grounded. Thus, the reduced compliance time could 
substantially disrupt certain operators. The FAA

[[Page 23583]]

considers that this is neither practicable nor in the public interest.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment. However, we invite you to send any written data, views, or 
arguments about this AD. Send your comments to an address listed under 
the ADDRESSES section. Include the docket number FAA-2016-5592 and 
Directorate Identifier 2016-NM-040-AD at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this AD. We will 
consider all comments received by the closing date and may amend this 
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 AD.

Costs of Compliance

    We estimate that this AD affects 43 airplanes of U.S. registry. We 
estimate the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
             Action                         Labor cost              Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
AFM revisions...................  1 work-hour x $85 per hour =                $0             $85          $3,655
                                   $85.
Rework..........................  40 work-hours x $85 per hour =               0           3,400         146,200
                                   $3,400.
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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.
    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

    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.

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA 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 adding the following new airworthiness 
directive (AD):

2016-08-12 The Boeing Company: Amendment 39-18488; Docket No. FAA-
2016-5592; Directorate Identifier 2016-NM-040-AD.

(a) Effective Date

    This AD is effective May 9, 2016.

(b) Affected ADs

    This AD affects AD 2016-06-08, Amendment 39-18439 (81 FR 14704, 
March 18, 2016) (``AD 2016-06-08'').

(c) Applicability

    This AD applies to The Boeing Company Model 787-8 and 787-9 
airplanes, certificated in any category, powered by General Electric 
(GE) GEnx-1B engines.

(d) Subject

    Air Transport Association (ATA) of America Code 72, engines.

(e) Unsafe Condition

    This AD was prompted by a recent engine fan blade rub event that 
caused an in-flight non-restartable power loss. We are issuing this 
AD to prevent susceptibility to heavy fan blade rubs, which could 
result in engine damage and a possible in-flight non-restartable 
power loss of one or both engines.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Airplane Flight Manual (AFM) Revision: Certificate Limitations

    Within 7 days after the effective date of this AD, revise the 
Certificate Limitations chapter of the applicable Boeing 787 AFM to 
include the statement provided in figure 1 to paragraph (g) of this 
AD. This may be done by inserting a copy of this AD into the AFM. 
Once accomplished, the AFM revision required by this paragraph 
terminates the requirements of paragraph (g) of AD 2016-06-08, and 
the AFM revision required by paragraph (g) of AD 2016-06-08 must be 
removed from the AFM.

[[Page 23584]]

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(h) AFM Revision: Operating Procedures

    Within 7 days after the effective date of this AD, revise the 
Operating Procedures chapter of the Boeing 787 AFM to include the 
statement provided in figure 2 to paragraph (h) of this AD. This may 
be done by inserting a copy of this AD into the AFM. Once 
accomplished, the AFM revision required by this AD terminates the 
requirements of paragraph (h) of AD 2016-06-08, and the AFM revision 
required by paragraph (h) of AD 2016-06-08 must be removed from the 
AFM.
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[GRAPHIC] [TIFF OMITTED] TR22AP16.037

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(i) Removal of Certain Dispatch Relief

    As of 7 days after the effective date of this AD: 
Notwithstanding the provisions of the operator's minimum equipment 
list (MEL), dispatch of an airplane is prohibited unless the 
equipment specified in paragraph (i)(1) and (i)(2) is operational.
    (1) At least one Engine Anti-Ice (EAI) Indication.
    (2) At least one Ice Detector.

(j) Engine Rework or Replacement

    For an airplane powered by two engines having any model number 
GEnx-1B64/P2, -1B67/P2, -1B70/P2, -1B70C/P2, -1B70/75/P2, or -1B74/
75/P2, and any GEnx engine

[[Page 23586]]

assembly part number 2447M10G01 or 2447M10G02: Before October 1, 
2016, do the actions specified by paragraph (j)(1) or (j)(2) of this 
AD.
    (1) Rework at least one engine in accordance with paragraph 3.B. 
or 3.C. of the Accomplishment Instructions of GE GEnx-1B Service 
Bulletin 72-0309 R00, dated March 11, 2016; or paragraph 3.B. or 
3.C. of the Accomplishment Instructions of GE GEnx-1B Service 
Bulletin 72-0314 R00, dated April 1, 2016. Although GE GEnx Service 
Bulletins GEnx-1B 72-0314 R00, dated April 1, 2016; and GEnx-1B 72-
0309 R00, dated March 11, 2016; specify submitting certain tip 
clearance measurements to GE, no report is required by this AD.
    (2) Remove at least one engine and replace with an engine that 
is eligible for installation that is not identified in the 
introductory text to paragraph (j) of this AD.

(k) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle Aircraft Certification Office (ACO), 
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 the ACO, send it to the 
attention of the person identified in paragraph (l) of this AD. 
Information may be emailed to: [email protected].
    (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.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair, modification, or alteration required by this AD 
if it is approved by the Boeing Commercial Airplanes Organization 
Designation Authorization (ODA) that has been authorized by the 
Manager, Seattle ACO, to make those findings. To be approved, the 
repair method, modification deviation, or alteration deviation must 
meet the certification basis of the airplane, and the approval must 
specifically refer to this AD.

(l) Related Information

    For more information about this AD, contact Sue Lucier, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle ACO, 
1601 Lind Avenue SW., Renton, WA 98057-3356; phone: 425-917-6438; 
fax: 425-917-6590; email: [email protected].

(m) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (3) The following service information was approved for IBR on 
May 9, 2016.
    (i) GE GEnx-1B Service Bulletin 72-0314 R00, dated April 1, 
2016.
    (ii) Reserved.
    (4) The following service information was approved for IBR on 
March 18, 2016 (81 FR 14704, March 18, 2016).
    (i) GE GEnx-1B Service Bulletin 72-0309 R00, dated March 11, 
2016.
    (ii) Reserved.
    (5) For service information identified in this AD, contact 
General Electric Company, GE Aviation, Room 285, 1 Neumann Way, 
Cincinnati, OH 45215; phone: 513-552-3272; email: 
[email protected].
    (6) You may view this service information at the FAA, Transport 
Airplane Directorate, 1601 Lind Avenue SW., Renton, WA. For 
information on the availability of this material at the FAA, call 
425-227-1221.
    (7) You may view this service information that is incorporated 
by reference 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.

    Issued in Burlington, Massachusetts, on April 7, 2016.
Ann C. Mollica,
Acting Manager, Engine & Propeller Directorate, Aircraft Certification 
Service.
    Issued in Renton, Washington, on April 12, 2016.
Victor Wicklund,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2016-09000 Filed 4-21-16; 8:45 am]
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