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Docket ID: [Docket No. FAA-2005-23500; Directorate Identifier 2005-NE-46-AD; Amendment 39-15223; AD 2007-21-05]
RIN ID: RIN 2120-AA64
SUBJECT CATEGORY: Airworthiness Directives; International Aero Engines (IAE) V2500 Series Turbofan Engines
DOCUMENT SUMMARY: The FAA is adopting a new airworthiness directive (AD) for
International Aero Engines (IAE) V2500 series turbofan engines. This AD
requires repetitive monitoring of N2 vibration on all IAE V2500 series
engines to identify engines that might have a cracked high pressure
turbine (HPT) stage 2 air seal. This AD results from a report that HPT stage 2 air seals
[[Page 57855]]
have developed cracks. We are issuing this AD to prevent uncontained
failure of the HPT stage 2 air seal.
SUMMARY: International Aero Engines,
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) 6475527) is provided in
the ADDRESSES section. Comments will be available in the AD docket shortly after receipt.
We provided the public the opportunity to participate in the development of this AD. We have considered the comments received. Comments
The Modification and Replacement Parts Association states that the proposed AD does not list the part number(s) of seals requiring monitoring and replacement. We agree. To date, the following part numbers have failed: 2A3179, 2A3185, and 2A3425. However, all old design HPT stage 2 seals are subject to failure and should be vibration monitored and removed as required. We included a complete list of HPT stage 2 air seal part numbers in paragraph (c) of this AD.
The Air Transport Association and Delta Airlines state that we should better define the methodology for monitoring and determining trend slope. We disagree. Although these requirements are complex, they can be completed by trained personnel. We did not change the AD. Tracking Compliance
Delta Airlines states that we should provide guidance for tracking compliance with this AD, as current instructions are inadequate. We disagree. Operators should establish a system for showing compliance to this AD if they do not already have such a system. We did not change the AD.
Delta Airlines also states that we should include terminating action for the AD so they can estimate costs. We disagree. Terminating action is not currently available for the model V2500A1 engine. Further, we discuss costs in the Costs of Compliance section of the AD. We did not change the AD.
Japan Airlines International states that vibration trend monitoring is not appropriate for an AD. The airline states that, because of the complex and subjective nature of vibration trend monitoring, accurate measurements are not possible. Therefore, trend monitoring is appropriate as a supplemental, nonmandatory activity only. We disagree. Vibration trend monitoring is successful in detecting cracked HPT seals. Although results are somewhat subjective, the system is the most practical way to prevent an unsafe condition due to cracked HPT seals. We did not change the AD.
Japan Airlines International also states that industry needs a ground system to monitor vibration trends. We agree that a system to hold collected data and calculate trends as they occur is needed, however, defining requirements for that system is beyond the scope of this AD.
United Airlines states that we should permit vibration data averaging and smoothing. They state that not allowing averaging will increase the chances of false alerts. We disagree. Experience indicates that averaging or smoothing might mask evidence of a badly cracked seal before a piece becomes liberated. We did not change the AD. Clarify Service Bulletin Instructions
Japan Airlines International states that we should clarify
International Aero Engines service bulletin (SB) instructions regarding
how gaps allowed by the Mandatory Minimum Equipment List (MMEL) effect
data. MMEL allows a 10day down time for the vibration trend monitoring
system. We disagree. IAE service instructions allow a down time of 50
cycles, approximately 10 days for most operators. If operators require
more time, they may request an AMOC. We did not change the AD. Manufacturer's Suggestions
IAE suggests the following:
We have carefully reviewed the available data, including the
comments received, and determined that air safety and the public interest require adopting
[[Page 57856]]
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.
We estimate that this AD will affect 1,022 engines installed on airplanes of U.S. registry. We also estimate that it would take about 2 workhours per engine to perform the actions, and that the average labor rate is $80 per workhour. Required parts would cost about $97,040 per engine. Based on these figures, we estimate the total cost of the AD to U.S. operators to be $99,338,400.
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.
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.
Air transportation, Aircraft, Aviation safety, Incorporation by reference, Safety.
Adoption of the Amendment
Accordingly, under the authority delegated to me by the Administrator,
the Federal Aviation Administration amends 14 CFR part 39 as follows: PART 39AIRWORTHINESS 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:
20072105 International Aero Engines: Amendment 3915223. Docket No. FAA200523500; Directorate Identifier 2005NE46AD.
Effective Date
(a) This airworthiness directive (AD) becomes effective November 15, 2007.
Affected ADs
(b) None.
Applicability
(c) This AD applies to International Aero Engines (IAE) model
V2500A1, V2522A5, V2524A5, V2527A5, V2527EA5, V2527MA5, V2530
A5, V2533A5, V2525D5, and V2528D5 turbofan engines with high
pressure turbine (HPT) stage 2 air seals, part numbers (P/Ns)
2A0487, 2A1159, 2A1160, 2A3108, 2A3179, 2A3185, 2A3425, and 2A3596,
installed. These engines are installed on, but not limited to, Airbus A319, A320, A321, and Boeing MD90 airplanes.
Unsafe Condition
(d) This AD results from a report that HPT stage 2 air seals
have developed cracks. We are issuing this AD to prevent uncontained failure of the HPT stage 2 air seal.
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.
Monitoring N2 Vibration on All IAE Model V2500A1 and V2522A5, V2524
A5, V2527A5, V2527EA5, V2527MA5, V2530A5, and V2533A5 Engines
(f) For IAE model V2530A5 and V2533A5 engines operated at
30,000 or 33,000 pounds of thrust, or for model V2522A5, V2524A5,
V2527A5, V2527EA5, and V2527MA5 engines that have ever operated
in the 30,000 or 33,000 pound thrust range, begin monitoring for N2
vibration trend if the HPT stage 2 air seal reaches 4,000 cycles sincenew (CSN) or more.
(g) For IAE model V2500A1 and V2522A5, V2524A5, V2527A5,
V2527EA5, and V2527MA5 engines operated below 30,000 pounds of
thrust, begin monitoring for N2 vibration trend if the HPT stage 2 air seal reaches 6,000 CSN.
(h) Monitor N2 vibration trend of each engine for every 100 to 150 cycles of engine operation as follows:
(1) Use the Accomplishment Instructions of IAE Service Bulletin
(SB) V2500ENG720500, Revision 1, dated July 14, 2006, to gather and monitor steadystate cruise N2 vibration data.
(2) For a trend that has a slope of 0.001 units per cycle or
greater and less than 0.003 units per cycle, remove the seal 250
cycles from the point at which the slope begins to increase and do not reinstall it in any V2500 engine.
(3) For a trend that has a slope of 0.003 units per cycle or
greater, remove the seal in 10 cycles and do not reinstall it in any V2500 engine.
(4) If a through crack is found in the front fillet radius of the HPT stage 2 air seal, remove the following:
(i) For the A1 model engine, remove the HPT stage 1 and 2 disks
and HPT stage 1 rear air seals (64 per engine) and do not reinstall them in any V2500 engine.
(ii) For all A5 engine models, remove the HPT stage 1 disk and
the HPT stage 1 rear air seals (64 per engine) and do not reinstall them in any V2500 engine.
(5) Use Section 3, Accomplishment Instructions, of IAE SB V2500 ENG720502, Revision 1, dated March 15, 2006, for removal
procedures.
Monitoring N2 Vibration on All IAE Model V2525D5 and V2528D5 Engines
(i) For all IAE model V2500D5 series engines, begin monitoring
for N2 vibration trend if the HPT stage 2 air seal reaches 6,000 CSN or more.
(j) Monitor N2 vibration trend of each engine for every 100 to 150 cycles of engine operation as follows:
(1) Use Section 3, Accomplishment Instructions, of IAE SB V2500
ENG720501, Revision 1, dated July 14, 2006, to gather and monitor the steadystate cruise N2 vibration data.
(2) If an increasing trend that has a slope of 0.0007 units per
cycle or greater, and less than 0.002 units per cycle is observed,
remove the HPT stage 2 air seal within 250 cycles from the point at
which the slope begins to increase and do not reinstall it in any V2500 engine.
(3) If an increasing trend that has a slope of 0.002 units per
cycle or greater is observed, remove the HPT stage 2 air seal within 10 cycles and do not reinstall it in any V2500 engine.
(4) If a through crack is found in the front fillet radius of
the HPT stage 2 air seal of D5 model engines, remove the HPT stage 1
disk and HPT rear air seals (64 per engine) and do not reinstall them in any V2500 engine.
(5) Use Section 3, Accomplishment Instructions, of IAE SB V2500 ENG720502, dated March 15, 2006, for removal procedures.
[[Page 57857]]
Removal of HPT Stage 2 Air Seals at Opportunity
(k) For all engines, when the HPT stage 2 air seal reaches 2,000
CSN, remove the HPT stage 2 air seal at the next separation of the
HPT stage 1 and 2 rotors and do not reinstall it in any V2500 engine.
Definition
(l) For the purposes of this AD, ``At Opportunity'' is defined
as when the engine is disassembled, the HPT stage 2 seal is exposed,
and the HPT stage 1 and 2 rotors are separated after 2,000 CSN.
(m) The Accomplishment Instructions of IAE SB V2500ENG720502,
Revision 1, dated March 15, 2006, provide information on removing the HPT stage 2 air seal.
Alternative Methods of Compliance
(n) 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
(o) Contact James Rosa, Aerospace Engineer, Engine Certification
Office, FAA, Engine and Propeller Directorate, 12 New England
Executive Park, Burlington, MA 01803; email: james.rosa@faa.gov,
telephone (781) 2387152; fax (781) 2387199, for more information about this AD.
Material Incorporated by Reference
(p) You must use the Accomplishment Instructions (Section 3.) of
International Aero Engines (IAE) Service Bulletin (SB) V2500ENG72
0500, Revision 1, dated July 14, 2006; IAE SB V2500ENG720501,
Revision 1, dated July 14, 2006; or IAE SB V2500ENG720502,
Revision 1, dated March 15, 2006, to perform the actions required by
this AD. The Director of the Federal Register approved the
incorporation by reference of these service bulletins in accordance
with 5 U.S.C. 552(a) and 1 CFR part 51. Contact International Aero
Engines AG, 400 Main Street, East Hartford, CT 06108; telephone:
(860) 5655515; fax: (860) 5655510 for a copy of this service
information. 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 2027416030, or go to:
http://www.archives.gov/federalregister/cfr/ibrlocations.html.
Issued in Burlington, Massachusetts, on October 2, 2007. Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft Certification Service.
[FR Doc. E719924 Filed 101007; 8:45 am]
BILLING CODE 491013P
FOR FURTHER INFORMATION CONTACT James Rosa, Aerospace Engineer, Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; telephone (781) 2387152; fax (781) 2387199.
14 CFR Part 39 40 CFR Part 52 14 CFR Part 71 33 CFR Part 165 50 CFR Part 679 47 CFR Part 73 26 CFR Part 1 40 CFR Part 180 33 CFR Part 117 50 CFR Part 17 44 CFR Part 67 50 CFR Part 648 14 CFR Part 97 40 CFR Part 63 33 CFR Part 100 50 CFR Part 622 50 CFR Part 660 26 CFR Part 301 44 CFR Part 65 39 CFR Part 111 40 CFR Part 300 6 CFR Part 5 40 CFR Part 271 47 CFR Part 64 40 CFR Parts 52 and 81 50 CFR Part 665 10 CFR Part 50 44 CFR Part 64 49 CFR Part 571 39 CFR Part 3020