81 FR 60582 - Airworthiness Directives; International Aero Engines AG Turbofan Engines

DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration

Federal Register Volume 81, Issue 171 (September 2, 2016)

We are adopting a new airworthiness directive (AD) for certain International Aero Engines AG (IAE) V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, and V2533-A5 turbofan engines. This AD was prompted by the fracture of the high- pressure turbine (HPT) stage 2 hub during flight, which resulted in an in-flight shutdown (IFSD), undercowl fire, and smoke in the cabin. This AD requires inspecting the HPT stage 1 hub and HPT stage 2 hub, and, if necessary, their replacement with parts that are eligible for installation. We are issuing this AD to prevent failure of the HPT stage 1 or HPT stage 2 hubs, which could result in uncontained HPT blade release, damage to the engine, and damage to the airplane.

[Federal Register Volume 81, Number 171 (Friday, September 2, 2016)]
[Rules and Regulations]
[Pages 60582-60585]
From the Federal Register Online  [www.thefederalregister.org]
[FR Doc No: 2016-21061]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2016-4123; Directorate Identifier 2016-NE-06-AD; 
Amendment 39-18640; AD 2016-18-10]
RIN 2120-AA64


Airworthiness Directives; International Aero Engines AG Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are adopting a new airworthiness directive (AD) for certain 
International Aero Engines AG (IAE) V2522-A5, V2524-A5, V2525-D5, 
V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, and V2533-A5 
turbofan engines. This AD was prompted by the fracture of the high-
pressure turbine (HPT) stage 2 hub during flight, which resulted in an 
in-flight shutdown (IFSD), undercowl fire, and smoke in the cabin. This 
AD requires inspecting the HPT stage 1 hub and HPT stage 2 hub, and, if 
necessary, their replacement with parts that are eligible for 
installation. We are issuing this AD to prevent failure of the HPT 
stage 1 or HPT stage 2 hubs, which could result in uncontained HPT 
blade release, damage to the engine, and damage to the airplane.

DATES: This AD is effective October 7, 2016.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of October 7, 
2016.

[[Page 60583]]


ADDRESSES: For service information identified in this final rule, 
contact International Aero Engines AG, 400 Main Street, East Hartford, 
CT 06118; phone: 800-565-0140; email: [email protected]; Internet: 
http://fleetcare.pw.utc.com. You may view this referenced service 
information at the FAA, Engine & Propeller Directorate, 1200 District 
Avenue, Burlington, MA. For information on the availability of this 
material at the FAA, call 781-238-7125. It is also available on the 
internet at http://www.regulations.gov by searching for and locating 
Docket No. FAA-2016-4123.

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-
4123; 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 
other information. The address for the Docket Office (phone: 800-647-
5527) is Document Management Facility, U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE., Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Brian Kierstead, Aerospace Engineer, 
Engine Certification Office, FAA, Engine & Propeller Directorate, 1200 
District Avenue, Burlington, MA 01803; phone: 781-238-7772; fax: 781-
238-7199; email: [email protected].

SUPPLEMENTARY INFORMATION:

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 by adding an AD that would apply to certain IAE V2522-A5, 
V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, 
and V2533-A5 turbofan engines. The NPRM published in the Federal 
Register on April 5, 2016 (81 FR 19516). The NPRM was prompted by the 
fracture of the HPT stage 2 hub during flight, which resulted in an 
IFSD, undercowl fire, and smoke in the cabin. The NPRM proposed to 
require inspecting the HPT stage 1 hub and HPT stage 2 hub, and, if 
necessary, their replacement with parts that are eligible for 
installation. We are issuing this AD to prevent failure of the HPT 
stage 1 or HPT stage 2 hubs, which could result in uncontained HPT 
blade release, damage to the engine, and damage to the airplane.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the NPRM and 
the FAA's response to each comment.

Request To Add Credit for Previous Action

    IAE and Cathay Pacific requested that we update this AD to refer to 
Non-Modification Service Bulletin (NMSB) V2500-ENG-72-0661 Revision 2, 
dated May 27, 2016, and allow credit for previous actions to include 
hubs inspected and cleared to IAE's NMSB V2500-ENG-72-0661, Original 
issue, dated November 10, 2015; and Revision 1, dated February 5, 2016.
    We agree. We updated this AD to refer to NMSB V2500-ENG-72-0661, 
Revision 2, dated May 27, 2016. We are also including a Credit for 
Previous Actions paragraph that references IAE NMSB V2500-ENG-72-0661, 
Original issue, dated November 10, 2015; and Revision 1, dated February 
5, 2016.

Request To Change Compliance Time

    IndiGo and Cathay Pacific stated that the NPRM uses hub cycles 
since new (CSN) to determine when hub inspections are required. 
However, the commenters requested that this AD be specific as to the 
date on which CSN of the hubs are established. The IAE NMSB, Compliance 
Section, Table 1 refers to a compliance time within ``Hub cycles as of 
February 1, 2016'', but the NPRM does not mention any date. One 
commenter states that compliance to the February 1, 2016 date will not 
provide adequate planning time to operators for compliance.
    We agree. This AD requires actions after the effective date of this 
AD. Therefore, we changed paragraphs (e)(1)(i), (ii), (iii), and (iv) 
of this AD to read ``for hubs with [xxx] CSN on the effective date of 
this AD''.

Request To Change Compliance Time

    Germanwings GmbH requested that the effective date of this AD be 
aligned with IAE NMSB V2500-ENG-72-0661, Revision 2, dated May 27, 
2016, which refers to ``Hub cycles as of February 1, 2016.'' The 
commenter states that the difference in time between the effective date 
of this AD and February 1, 2016 listed in the NMSB will cause a 
mismatch in the compliance time.
    We disagree. Basing the compliance times on the effective date of 
this AD is less restrictive than the IAE NMSB, so complying with this 
AD based on hub CSN as of the earlier NMSB date, would satisfy this AD. 
We did not change this AD.

Request To Change Shop Visit Definition

    Delta Airlines and one other commenter requested that we change the 
definition of shop visit from separation of pairs of major mating 
engine flanges, to either piece-part exposure, HPT flange separation, 
or disassembly of the HPT rotor and stator assemblies.
    Delta Airlines stated that compliance at the next shop visit, as 
defined in this AD would result in unnecessary cost and extended shop 
time. The other commenter stated that changing the definition would 
allow more flexibility in fleet management. Both commenters state that 
inspection at the next shop visit is not needed, since removal of the 
suspect hubs within the proposed cycle limits will provide an 
acceptable level of safety.
    We disagree. Allowing all engines to operate until their respective 
cycle limit would not provide an acceptable level of safety. By 
inspecting a specific quantity of engines that will be inducted into 
the shop before the cycle limit occurs, the safety risk assessment is 
satisfied. Therefore, waiting until the piece-part exposure, HPT flange 
separation, or the cycle threshold in lieu of inspection at the next 
shop visit, does not meet the requirement of this AD. We did not change 
this AD.

Conclusion

    We reviewed the relevant data, considered the comments received, 
and determined that air safety and the public interest require adopting 
this AD with the changes described previously. We have determined that 
these minor changes:
     Are consistent with the intent that was proposed in the 
NPRM (81 FR 19516, April 5, 2016) for correcting the unsafe condition; 
and
     Do not add any additional burden upon the public than was 
already proposed in the NPRM (81 FR 19516, April 5, 2016).

Related Service Information Under 1 CFR Part 51

    We reviewed IAE NMSB V2500-ENG-72-0661, Revision 2, dated May 27, 
2016. The NMSB describes procedures for inspecting the HPT stage 1 and 
stage 2 hubs. 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.

[[Page 60584]]

Costs of Compliance

    We estimate that this AD affects 668 engines with 947 hubs 
installed on airplanes of U.S. registry. Some of the 668 engines have 
two hubs installed. We estimate that it would take about 8 hours per 
hub to perform the piece-part inspection. The average labor rate is $85 
per hour. We estimate that 568 hubs will require replacement. We 
estimate the pro-rated cost to replace an HPT stage 1 hub to be $50,271 
and the pro-rated cost to replace an HPT stage 2 hub to be $40,063. 
Based on these figures, we estimate the cost of this AD on U.S. 
operators to be $26,298,816.

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):

2016-18-10 International Aero Engines AG: Amendment 39-18640; Docket 
No. FAA-2016-4123; Directorate Identifier 2016-NE-06-AD.

(a) Effective Date

    This AD is effective October 7, 2016.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to International Aero Engines AG (IAE) V2522-A5, 
V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-
A5, and V2533-A5 engines with either of the following installed:
    (1) High-pressure turbine (HPT) stage 1 hub, part number (P/N) 
2A5001, with a serial number (S/N) listed in Table 1, Appendix A, of 
IAE Non-Modification Service Bulletin (NMSB) V2500-ENG-72-0661, 
Revision 2, dated May 27, 2016; or
    (2) HPT stage 2 hub, P/N 2A4802, with an S/N listed in Table 2, 
Appendix A, of IAE NMSB V2500-ENG-72-0661, Revision 2, dated May 27, 
2016.

(d) Unsafe Condition

    This AD was prompted by the fracture of the HPT stage 2 hub 
during flight, which resulted in an in-flight shutdown, undercowl 
fire, and smoke in the cabin. We are issuing this AD to prevent 
failure of the HPT stage 1 or HPT stage 2 hubs, which could result 
in uncontained HPT blade release, damage to the engine, and damage 
to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) Inspect the HPT stage 1 hub, P/N 2A5001, and HPT stage 2 
hub, P/N 2A4802, at the next shop visit or as follows, whichever 
comes first:
    (i) For hubs with 0 to 7,000 CSN on the effective date of this 
AD, before accumulating 13,000 CSN;
    (ii) For hubs with 7,001 to 11,000 CSN on the effective date of 
this AD, within 6,000 cycles from the effective date of this AD or 
before accumulating 15,000 CSN, whichever occurs first;
    (iii) For hubs with 11,001 to 15,500 CSN on the effective date 
of this AD, within 4,000 cycles from the effective date of this AD 
or before accumulating 17,000 CSN, whichever occurs first;
    (iv) For hubs with 15,501 CSN or more on the effective date of 
this AD, within 1,500 cycles from the effective date of this AD.
    (2) Use Accomplishment Instructions, paragraphs 2.A., 2.C., and 
2.D., of IAE NMSB V2500-ENG-72-0661, Revision 2, dated May 27, 2016, 
to inspect the HPT stage 1 hub, P/N 2A5001.
    (3) Use Accomplishment Instructions, paragraphs 2.E., 2.G., and 
2H., of IAE NMSB V2500-ENG-72-0661, Revision 2, dated May 27, 2016 
to inspect the HPT stage 2 hub, P/N 2A4802.
    (4) Remove from service any HPT stage 1 hub, P/N 2A5001, or HPT 
stage 2 hub, P/N 2A4802, that fails the inspections required by 
paragraphs (e)(2) and (e)(3) of this AD, and replace with a part 
that is eligible for installation.

(f) Definition

    For the purpose of this AD, a ``shop visit'' is the induction of 
an engine into the shop for maintenance involving the separation of 
pairs 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.

(g) Credit for Previous Actions

    If you performed inspection and or replacement using IAE NMSB 
V2500-ENG-72-0661, original issue, dated November 10, 2015 or NMSB 
V2500-ENG-72-0661, Revision 1, dated February 5, 2016, you met the 
requirements of paragraphs (e)(2) and (e)(3) of this AD.

(h) Alternative Methods of Compliance (AMOCs)

    The Manager, Engine Certification Office, FAA, may approve AMOCs 
for this AD. Use the procedures found in 14 CFR 39.19 to make your 
request. You may email your request to: [email protected].

(i) Related Information

    For more information about this AD, contact Brian Kierstead, 
Aerospace Engineer, Engine Certification Office, FAA, Engine & 
Propeller Directorate, 1200 District Avenue, Burlington, MA 01803; 
phone: 781-238-7772; fax: 781-238-7199; email: 
[email protected].

(j) 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.
    (i) International Aero Engines AG Non-Modification Service 
Bulletin V2500-ENG-72-0661, Revision 2, dated May 27, 2016.
    (ii) Reserved.

[[Page 60585]]

    (3) For International Aero Engines AG service information 
identified in this AD, contact International Aero Engines AG, 400 
Main Street, East Hartford, CT 06118; phone: 800-565-0140; email: 
[email protected]; Internet: http://fleetcare.pw.utc.com.
    (4) You may view this service information at FAA, Engine & 
Propeller Directorate, 1200 District Avenue, Burlington, MA. For 
information on the availability of this material at the FAA, call 
781-238-7125.
    (5) 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 August 26, 2016.
Colleen M. D'Alessandro,
Manager, Engine & Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 2016-21061 Filed 9-1-16; 8:45 am]
 BILLING CODE 4910-13-P