[Federal Register Volume 65, Number 127 (Friday, June 30, 2000)]
[Proposed Rules]
[Pages 40555-40557]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 00-16643]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NE-21-AD]
RIN 2120-AA64


Airworthiness Directives; International Aero Engines AG V2500-A5/
D5 Series Turbofan Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: This document proposes the adoption of a new airworthiness 
directive (AD) that is applicable to certain International Aero Engines 
(IAE) V2500-A5/D5 series turbofan engines, identified by serial number. 
This proposal would require the removal of engines assembled with an 
improper High Pressure Turbine (HPT) module configuration from service 
prior to accumulating 5,100 or 7,600 cycles in the improper 
configuration, or at the next shop visit, depending on the type of 
improper HPT configuration, and restoration to type design. This 
proposed amendment is prompted by reports of engines that do not 
conform to the engine type design, which could cause a Low Cycle 
Fatigue (LCF) life reduction of the HPT stage 1 disk. The actions 
specified by the proposed AD are intended to restore engines to type 
design configuration and to prevent possible LCF failure of the HPT 
stage 1 disk, which could result in an uncontained engine failure and 
damage to the airplane.

DATES: Comments must be received by July 31, 2000.

ADDRESSES: Submit comments to the Federal Aviation Administration 
(FAA), New England Region, Office of the Regional Counsel, Attention: 
Rules Docket No. 2000-NE-21-AD, 12 New England Executive Park, 
Burlington, MA 01803-5299. Comments may also be submitted to the Rules 
Docket by using the following Internet address: ``[email protected]''. Comments may be inspected at this location between 
8 a.m. and 4:30 p.m., Monday through Friday, except Federal holidays. 
The service information referenced in this AD may be obtained from 
International Aero Engines, 400 Main Street, East Hartford, CT 06108; 
telephone (860) 565-5515; fax (860) 565-5510. This information may be 
examined at the FAA, New England Region, Office of the Regional 
Counsel, 12 New England Executive Park, Burlington, MA.

FOR FURTHER INFORMATION CONTACT: Diane Cook, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803-5299; telephone 781-238-
7133, fax 781-238-7199.

SUPPLEMENTARY INFORMATION:

Comments Invited

    Interested persons are invited to participate in the making of the 
proposed rule by submitting such written data, views, or arguments, as 
they may desire. Communications should identify the Rules Docket number 
and be submitted to the address specified above. All communications 
received on or before the closing date for comments, specified above, 
will be considered before taking action on the proposed rule. The 
proposals contained in this notice may be changed in light of the 
comments received.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the proposed rule. All 
comments submitted will be available, both before and after the closing 
date for comments, in the Rules Docket for examination by interested 
persons. A report summarizing each FAA-public contact concerned with 
the substance of this proposal will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this notice must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2000-NE-21-AD.'' The postcard will be date stamped and 
returned to the commenter.

Availability of NPRMs

    Any person may obtain a copy of this NPRM by submitting a request 
to the FAA, New England Region, Office of the Regional Counsel, 
Attention: Rules Docket No. 2000-NE-21-AD, 12 New England Executive 
Park, Burlington, MA 01803-5299.

Discussion

    The Federal Aviation Administration (FAA) has received reports that 
during recent shop visits at various overhaul and repair facilities, 32 
V2500-A5/D5 series engines have been assembled with improper HPT module 
configurations. The improper HPT assemblies resulted from incorrect or 
incomplete incorporation of several IAE service bulletins (SB) required 
for proper assembly of the high secondary cooling airflow HPT stage 1 
turbine blades and cooling duct, which were

[[Page 40556]]

introduced as part of the V2533-A5 HPT configuration. The new high 
secondary cooling airflow HPT stage 1 blade and modified stage 1 HPT 
cooling duct assembly were introduced to improve the blade cooling and 
blade durability. This configuration became the new standard for all 
V2500-A5 and D5 series engines. Service Bulletins V2500-ENG-72-0242 and 
SB V2500-ENG-72-0241 introduced the ``high airflow'' HPT blades and 
stage 1 HPT cooling duct assembly, respectively, to the other V2500-A5/
D5 models. For engines with thrust ratings below 33K, the HPT module 
can be assembled with either the low airflow stage 1 HPT blades and low 
airflow or high airflow stage 1 HPT cooling duct assembly (pre SB 
V2500-ENG-72-0242 and pre or post SB V2500-ENG-72-0241, respectively) 
or with the high airflow stage 1 HPT blades and high airflow cooling 
duct assembly (post SB V2500-ENG-72-0242 and post SB V2500-ENG-72-0241, 
respectively). The FAA has reports of 32 engines that have been 
assembled with an intermix of high airflow and low airflow HPT 
hardware. There are five improper configurations of the HPT module in 
the field as defined below.

----------------------------------------------------------------------------------------------------------------
                                                                                                         Number
           Configuration              Stage 1 HPT blade     Stage 1 HPT cooling  Towel bar seals part   Affected
                                                               duct assembly          no. 2A0530        engines
----------------------------------------------------------------------------------------------------------------
X.................................  Full set of High Flow  Low Flow............   Installed..........         19
X*................................  3 or fewer High Flow.  Low Flow............  Installed...........          2
X'................................  2 High Flow..........  Low Flow............  Not Installed.......          1
Y.................................  Full set of High Flow  High Flow...........  Installed...........          9
Z.................................  Full set of Low Flow.  High Flow...........  Installed...........          1
Baseline: After installation of     Full set of High Flow  High Flow...........  Not Installed.......
 Service Bulletins (SB) 72-0242
 and SB 72-0241.
----------------------------------------------------------------------------------------------------------------

    Configuration X and X' result in higher temperature in the OD rim 
cavity of the HPT stage 1 disk than the design intended. The 
consequence of this disk rim temperature increase is a debit to the 
life of the disk. An engineering review has determined that if engines 
in configuration X are removed from service and restored to an approved 
configuration prior to accumulating 5,100 cycles in configuration X, 
the HPT disk assembled in an approved configuration will meet its 
chapter 5 life limit. The disk rim temperature increase for 
configuration X' engine is less severe than for the configuration X. An 
engineering review has determined that if the engine in configuration 
X' is removed from service and restored to an approved configuration 
prior to accumulating 7,600 cycles in configuration X', the HPT disk 
assembled in an approved configuration will meet its chapter 5 life 
limit.
    Configurations X*, Y, and Z do not effect the HPT disk rim 
temperatures significantly. However, these are not approved 
configurations. This proposed AD will require the removal of engines 
with HPT modules built to configuration X*, Y, or Z from service and 
the restoration to type design at the next shop visit.
    The actions specified by the proposed AD are intended to restore 
the engine to type design and prevent possible LCF failure of the stage 
1 HPT disk, which, if not corrected, could lead to an uncontained 
engine failure and damage to the airplane.

Service Information

    IAE has issued All Operators Wire (AOW) No. 1053, Issue 2, dated 
June 20, 2000, which identifies engines with HPT modules utilizing non 
type design configurations by serial numbers and by specific 
configurations. (configuration X, X*, X', Y, or Z).

Proposed Actions

    Since an unsafe condition has been identified that is likely to 
exist or develop on other engines of the same type design registered in 
the United States, the proposed AD would require the removal from 
service of certain V2500-A5/D5 series engines, identified by serial 
numbers, prior to accumulating 5,100 or 7,600 cycles in the improper 
configuration, or at the next shop visit, depending on the type of 
improper HPT module configuration and the restoration type design.

Economic Analysis

    There are approximately 32 engines in the worldwide fleet with the 
HPT module assembled in an improper configuration. The FAA estimates 
that 12 engines installed on aircraft of US registry would be removed 
from service before scheduled shop visits as a result of this proposed 
AD. The cost of early removal and restoration to type design will be 
approximately $6,000 per engine. Based on these figures, the total cost 
impact of the proposed AD on US operators is estimated to be $72,000.

Regulatory Impact

    This proposal does not have federalism implications, as defined in 
Executive Order 13132, because it 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. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this proposal.
    For the reasons discussed above, I certify that this proposed 
regulation (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) if promulgated, 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. A copy of the draft 
regulatory evaluation prepared for this action is contained in the 
Rules Docket. A copy of it may be obtained by contacting the Rules 
Docket at the location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration proposes to amend 
part 39 of the Federal Aviation Regulations (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. Section 39.13 is amended by adding the following new 
airworthiness directive:


[[Page 40557]]


International Aero Engines: Docket No. 2000-NE-21-AD.

    Applicability: International Aero Engines (IAE) V2500-A5 and 
V2500-D5 series turbofan engines listed by Serial Number (S/N) as 
follows: V10011, V10035, V10036, V10039, V10040, V10041, V10054, 
V10067, V10079, V10080, V10084, V10111, V10121, V10123, V10124, 
V10130, V10131, V10139, V10166, V10172, V10174, V10180, V10199, 
V10221, V10341, V20001, V20013, V20017, V20019, V20023, V20033, 
V20037.
    These engines are installed on, but not limited to, Airbus 
Industries A319, A320, A321 series, and McDonnell Douglas MD-90 
series airplanes.

    Note 1: This airworthiness directive (AD) applies to each engine 
identified in the preceding applicability provision, regardless of 
whether it has been modified, altered, or repaired in the area 
subject to the requirements of this AD. For engines that have been 
modified, altered, or repaired so that the performance of the 
requirements of this AD is affected, the owner/operator must request 
approval for an alternative method of compliance in accordance with 
paragraph (b) of this AD. The request should include an assessment 
of the effect of the modification, alteration, or repair on the 
unsafe condition addressed by this AD; and, if the unsafe condition 
has not been eliminated, the request should include specific 
proposed actions to address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To restore the engines to type design and to prevent possible 
low cycle fatigue (LCF) failure of the HPT stage 1 disk, which could 
lead to an uncontained engine failure and damage to the airplane, 
accomplish the following:

Removal and Restoration of the HPT Module

    (a) For those engines identified by serial numbers in Table 1 of 
this AD, with HPT modules built to configuration X, X', X*, Y, or Z, 
remove from service in accordance with Table 1 and restore the HPT 
module to type design in accordance with IAE All Operators Wire 
(AOW) 1053, Issue 2, dated 6/20/00.

                                                     Table 1
----------------------------------------------------------------------------------------------------------------
                                         HPT module
          Engine serial No.            configuration           HPT hardware          Reconfigure at or prior to:
----------------------------------------------------------------------------------------------------------------
V10084, V10035, V10036, V10039,                    X   High Flow Blades: Post SB72-  The earlier of the next
 V10130, V10011, V10040, V10079,                        0242; Low Flow Duct           shop visit; or
 V10080, V10124, V10123, V10111,                        Assembly: Pre SB72-0241;      accumulating either 5100
 V20013, V20017, V10172, V10174,                        Towel Bar Seals, P/N          cycles in service (CIS) in
 V20019, V10180, V20023.                                2A0530: Installed.            configuration X, or 100
                                                                                      CIS after the effective
                                                                                      date of this AD, whichever
                                                                                      occurs later.
V20037..............................              X'   2 High Flow Blades: Post      The earlier of the next
                                                        SB72-0242; Low Flow Duct or   shop visit; or
                                                        Assembly: Pre SB72-0241;      accumulating either 7600
                                                        Towel Bar Seals, P/N          CIS in configuration X',
                                                        2A0530: Not Installed.        or 100 CIS after the
                                                                                      effective date of this AD,
                                                                                      whichever occurs later.
V20001, V20033......................              X*   3 or fewer High Flow Blades:  Next Shop Visit.
                                                        Post SB72-0242; Low Flow
                                                        Duct Assembly: Pre SB72-
                                                        0241; Towel Bar Seals, P/N
                                                        2A0530: Installed.
V10199, V10166, V10054, V10131,                    Y   High Flow Blades: Post SB 72- Next Shop Visit.
 V10139, V10041, V10121, V10067,                        0242; High Flow Duct
 V10341.                                                Assembly: Post SB72-0241;
                                                        Towel Bar Seals, P/N
                                                        2A0530: Installed.
V10221..............................               Z   Low Flow Blades: Pre SB72-    Next Shop Visit.
                                                        0242; High Flow Duct
                                                        Assembly: Post SB72-0241;
                                                        Towel Bar Seals, P/N
                                                        2A0530: Installed.
----------------------------------------------------------------------------------------------------------------

Alternate Methods of Compliance

    (b) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Engine Certification Office (ECO). 
Operators shall submit their requests through an appropriate FAA 
Principal Maintenance Inspector, who may add comments and then send 
it to the Manager, ECO.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the ECO.

Ferry Flights

    (c) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the aircraft to a location where 
the requirements of this AD can be accomplished.

    Issued in Burlington, Massachusetts, on June 23, 2000.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 00-16643 Filed 6-29-00; 8:45 am]
BILLING CODE 4910-13-U