[Federal Register Volume 67, Number 32 (Friday, February 15, 2002)]
[Rules and Regulations]
[Pages 7061-7065]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 02-3579]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 98-ANE-66-AD; Amendment 39-12649; AD 2002-03-08]
RIN 2120-AA64


Airworthiness Directives; Pratt & Whitney PW4000 Series Turbofan 
Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), that is applicable to Pratt & Whitney PW4000 series turbofan 
engines. That AD currently requires revisions to the Time Limits 
Section of the manufacturer's Engine Manuals (EM's) to include required 
enhanced inspection of selected critical life-limited parts at each 
piece-part exposure. This amendment modifies the airworthiness 
limitations section of the manufacturer's manual and an air carrier's 
approved continuous airworthiness maintenance program to incorporate 
additional inspection requirements. An FAA study of in-service events 
involving uncontained failures of critical rotating engine parts has 
indicated the need for mandatory inspections. The mandatory inspections 
are needed to identify those critical rotating parts with conditions, 
which if allowed to continue in service, could result in uncontained 
failures. The actions specified by this AD are intended to prevent 
critical life-limited rotating engine part failure, which could result 
in an uncontained engine failure and damage to the airplane.

DATES: Effective date April 16, 2002.

ADDRESSES: This information may be examined, by appointment, at the 
Federal Aviation Administration (FAA), New England Region, Office of 
the Regional Counsel, 12 New England Executive Park, Burlington, MA.

FOR FURTHER INFORMATION CONTACT: Robert McCabe, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803-5299; telephone (781) 
238-7138, fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 2000-12-02, 
Amendment 39-11780 (65 FR 37473, June 15, 2000), which is applicable to 
Pratt & Whitney PW4000 series turbofan engines was published in the 
Federal Register on October 5, 2001 (66 FR 50888). That action proposed 
to modify the airworthiness limitations section of the manufacturer's 
manual and an air carrier's approved continuous airworthiness 
maintenance program to incorporate additional inspection requirements. 
An FAA study of in-service events involving uncontained failures of 
critical rotating engine parts has indicated the need for mandatory 
inspections. The mandatory inspections are needed to identify those 
critical rotating parts with conditions, which if allowed to continue 
in service, could result in uncontained failures.

Comments

    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the comments received.
    Two commenters state that EM part numbers 50A345, 50A751, and 
50A882 are incorrect and should be changed to the correct part numbers 
of 51A345, 51A751, and 50A822, respectively.
    The FAA agrees. The correct manual part numbers are included in 
this final rule.
    One commenter requests that the comment period of this AD be 
extended until the manufacturer issues the new inspection requirements 
in the EM's or, that the operator's compliance to the final rule of 
this AD be delayed for 30 days after the manufacturer publishes the new 
inspection procedures in the manufacturer's EM's.
    The FAA disagrees. The manufacturer has confirmed its ability to 
issue Temporary Revisions to the affected EM's within several weeks 
after the

[[Page 7062]]

effective date of this AD. The FAA believes that the nature and scope 
of the added inspections will not be significantly different from 
existing inspections. In addition, the effective date of this AD (and 
therefore the operator's compliance time period) has been extended to 
60 days after publication to allow ample time for the specific 
inspection procedures and requirements to be published by the 
manufacturer and then incorporated into the operator's maintenance 
programs. Operators may submit comments to the docket on the specific 
procedures once they are published, and the FAA will consider extending 
the effective date further or additional rulemaking, as necessary. The 
FAA does not believe, however, that this final rule need be delayed 
pending the publication of the inspection procedures, or that the 
initial compliance time be extended to accommodate the manufacturer's 
manual revision cycle.
    One commenter concurs with the intent of the AD as proposed.
    After careful review of the available data, including the comments 
noted above, the FAA has determined that air safety and the public 
interest require the adoption of the rule with the changes described 
previously. The FAA has determined that these changes will neither 
increase the economic burden on any operator nor increase the scope of 
the AD.

Economic Analysis

    No comments were received on the economic analysis contained in the 
proposed rules. The FAA has determined that the annual cost of 
complying with this AD does not create a significant economic impact on 
small entities.

Regulatory Analysis

    This final rule 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 final rule.
    For the reasons discussed above, I certify that this action (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 final evaluation has been prepared for 
this action and it 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.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends 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 removing Amendment 39-11780 (65 FR 
37473, June 15, 2000) and by adding a new airworthiness directive, 
Amendment 39-12649, to read as follows:

2002-03-08 Pratt & Whitney: Amendment 39-12649. Docket No. 98-ANE-
66-AD. Supersedes AD 2000-12-02, Amendment 39-11780.

    Applicability: Pratt & Whitney (PW) Model PW4050, PW4052, 
PW4056, PW4060, PW4060A, PW4060C, PW4062, PW4152, PW4156, PW4156A, 
PW4158, PW4160, PW4460, PW4462, PW4650, PW4164, PW4168, PW4168A, 
PW4074, PW4074D, PW4077, PW4077D, PW4084, PW4084D, PW4090, PW4090D, 
and PW4098 turbofan engines, installed on but not limited to Airbus 
A300, A310, and A330 series, Boeing 747, 767, and 777 series, and 
McDonnell Douglas MD-11 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 (c) 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 already done.
    To prevent critical life-limited rotating engine part failure, 
which could result in an uncontained engine failure and damage to 
the airplane, accomplish the following:

Inspections

    (a) Within the next 60 days after the effective date of this AD, 
revise the Time Limits Section (TLS) of the Engine Manuals (EM's), 
part numbers 50A443, 50A605, 50A822, 51A342, 51A345, and 51A751, as 
applicable, for Pratt & Whitney PW4050, PW4052, PW4056, PW4060, 
PW4060A, PW4060C, PW4062, PW4152, PW4156, PW4156A, PW4158, PW4160, 
PW4460, PW4462, PW4650, PW4164, PW4168, PW4168A, PW4074, PW4074D, 
PW4077, PW4077D, PW4084, PW4084D, PW4090, PW4090D, and PW4098 series 
turbofan engines; and for air carrier operations revise the approved 
mandatory inspections section of the continuous airworthiness 
maintenance program, to read as follows:

``MANDATORY INSPECTIONS

    (1) Perform inspections of the following parts at each piece-
part opportunity in accordance with the instructions provided in the 
PW4000 series Engine Cleaning, Inspection and Repair (CIR) Manuals:
    For Engine Manuals 50A443, 50A605, and 50A822, add the following 
table data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
Hub, Front Compressor...............  All.................        72-31-07  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Hub, Turbine, Front Assy (Stage 1)..  All.................        72-52-05  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Hub, Turbine, Intermediate Rear       All.................        72-52-06  Insp/Check-02.........        51A357
 (Stage 2).
----------------------------------------------------------------------------------------------------------------

    For Engine Manual 51A342, add the following table data:

[[Page 7063]]



----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
Hub, LPC Assembly...................  All.................        72-31-07  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Hub, Turbine, Front Assembly (Stage   All.................        72-52-05  Insp/Check-02.........        51A357
 1).
----------------------------------------------------------------------------------------------------------------
Seal--Air, HPT Stage 2..............  All.................        72-52-22  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Hub, Turbine, Rear (Stage 2)........  All.................        72-52-06  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------

    For Engine Manuals 51A345 and 51A751, add the following table 
data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
Hub, LPC Assembly...................  All.................        72-31-07  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Seal--Air, HPT Stage 1..............  All.................        72-52-19  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Hub, Turbine, Front Assembly (Stage   All.................        72-52-05  Insp/Check-02.........        51A750
 1).
----------------------------------------------------------------------------------------------------------------
Seal--Air, HPT Stage 2 Assembly.....  All.................        72-52-22  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Hub, Turbine rear Assembly (Stage 2)  All.................        72-52-06  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------

    For Engine Manuals 50A443, 50A605, and 50A822, add the following 
table data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
HPC Stage 5 Disk....................  All.................    \1\ 72-35-06  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
HPC Front Drum Rotor................  All.................    \1\ 72-35-07  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
HPC Rear Drum Rotor.................  All.................    \2\ 72-35-08  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
HPC Rear Drum Rotor.................  All.................    \3\ 72-35-10  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
\1\ For PW4000-94'' Phase I & III ONLY.
\2\ For PW4000-94'' Phase I ONLY.
\3\ For PW4000-94'' Phase III ONLY.

    For Engine Manual 51A342, add the following table data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
HPC Stage 5 Disk....................  All.................        72-35-06  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
HPC Front Drum Rotor................  All.................        72-35-07  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
HPC Rear Drum Rotor.................  All.................        72-35-10  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------

    For Engine Manuals 51A345 and 51A751, add the following table 
data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
HPC Stage 5 Disk....................  All.................        72-35-06  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
HPC Front Drum Rotor................  All.................        72-35-07  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
HPC Rear Drum Rotor.................  All.................        72-35-10  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
HPC Stage 15 Disk...................  All.................        72-35-92  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
HPT Stage 1 Airseal.................  All.................        72-52-19  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
HPT Front Hub.......................  All.................        72-52-05  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
HPT Stage 2 Airseal.................  All.................        72-52-22  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
HPT Rear Hub........................  All.................        72-52-06  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------

    For Engine Manuals 50A443, 50A605 and 50A822, add the following 
table data:

[[Page 7064]]



----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR Manual
----------------------------------------------------------------------------------------------------------------
Stage 3 LPT Disk....................  All.................        72-53-13  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Stage 4 LPT Disk....................  All.................        72-53-14  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Stage 5 LPT Disk....................  All.................        72-53-15  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Stage 6 LPT Disk....................  All.................        72-53-16  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------

    For Engine Manual 51A342, add the following table data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
Stage 3 LPT Disk....................  All.................        72-53-13  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Stage 4 LPT Disk....................  All.................        72-53-14  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Stage 5 LPT Disk....................  All.................        72-53-15  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Stage 6 LPT Disk....................  All.................        72-53-16  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------
Stage 7 LPT Disk....................  All.................        72-53-61  Insp/Check-02.........        51A357
----------------------------------------------------------------------------------------------------------------

    For Engine Manual 51A345, add the following table data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
Stage 3 LPT Disk....................  All.................        72-53-13  Insp/Check-02, Config-        51A750
                                                                             1.
----------------------------------------------------------------------------------------------------------------
Stage 4 LPT Disk....................  All.................        72-53-14  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Stage 5 LPT Disk....................  All.................        72-53-60  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Stage 6 LPT Disk....................  All.................        72-53-16  Insp/Check-02, Config-        51A750
                                                                             1.
----------------------------------------------------------------------------------------------------------------
Stage 7 LPT Disk....................  All.................        72-53-72  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Stage 8 LPT Disk....................  All.................        72-53-62  Insp/Check-02, Config-        51A750
                                                                             1.
----------------------------------------------------------------------------------------------------------------
Stage 9 LPT Disk....................  All.................        72-53-63  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------

    For Engine Manual 51A751, add the following table data:

----------------------------------------------------------------------------------------------------------------
                                                              CIR manual
          Part nomenclature                 Part No.            section     CIR manual  inspection   CIR manual
----------------------------------------------------------------------------------------------------------------
Stage 3 LPT Disk....................  All.................        72-53-13  Insp/Check-02, Config-        51A750
                                                                             2 See Note (1).
----------------------------------------------------------------------------------------------------------------
Stage 4 LPT Disk....................  All.................        72-53-14  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Stage 5 LPT Disk....................  All.................        72-53-60  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Stage 6 LPT Disk....................  All.................        72-53-16  Insp/Check-02, Config-        51A750
                                                                             2 See Note (1).
----------------------------------------------------------------------------------------------------------------
Stage 7 LPT Disk....................  All.................        72-53-72  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
Stage 8 LPT.........................  All.................        72-53-62  Insp/Check-02, Config-        51A750
                                                                             2 See Note (1).
----------------------------------------------------------------------------------------------------------------
Stage 9 LPT Disk....................  All.................        72-53-63  Insp/Check-02.........        51A750
----------------------------------------------------------------------------------------------------------------
\1\ FPI method only.

    (2) For the purposes of these mandatory inspections, piece-part 
opportunity means:
    (i) The part is considered completely disassembled when 
accomplished in accordance with the disassembly instructions in the 
manufacture's EM's to either the part detail or part assembly level 
part numbers for the parts listed in the Tables above, and
    (ii) The part has accumulated more than 100 cycles in service 
since the last piece-part opportunity inspection, provided that the 
part was not damaged or related to the cause for its removal from 
the engine.''
    (b) Except as provided in paragraph (c) of this AD, and 
notwithstanding contrary provisions in Sec. 43.16 of the Federal 
Aviation Regulations (14 CFR 43.16), these mandatory inspections 
must be performed only in accordance with the Time Limits Section of 
the manufacturer's EM's.

[[Page 7065]]

Alternative Methods of Compliance

    (c) 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 must submit their request 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.

Special Flight Permits

    (d) Special flight permits may be issued in accordance with 
Secs. 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 
21.197 and 21.199) to operate the airplane to a location where the 
requirements of this AD can be done.

Continuous Airworthiness Maintenance Program

    (e) FAA-certificated air carriers that have an approved 
continuous airworthiness maintenance program in accordance with the 
record-keeping requirement of Sec. 121.369(c) of the Federal 
Aviation Regulations (14 CFR 121.369(c)) must maintain records of 
the mandatory inspections that result from revising the Time Limits 
Section of the EM's and the air carrier's continuous airworthiness 
program. Alternatively, certificated air carriers may establish an 
approved system of record retention that provides a method for 
preservation and retrieval of the maintenance records that include 
the inspections resulting from this AD, and include the policy and 
procedures for implementing this alternate method in the air 
carrier's maintenance manual required by Sec. 121.369(c) of the 
Federal Aviation Regulations (14 CFR 121.369(c)); however, the 
alternate system must be accepted by the appropriate PMI and require 
the maintenance records be maintained either indefinitely or until 
the work is repeated. Records of the piece-part inspections are not 
required under Sec. 121.380(a)(2)(vi) of the Federal Aviation 
Regulations (14 CFR 121.380(a)(2)(vi)). All other operators must 
maintain the records of mandatory inspections required by the 
applicable regulations governing their operations.

    Note 3:
    The requirements of this AD have been met when the EM changes 
are made and air carriers have modified their continuous 
airworthiness maintenance plans to reflect the requirements in the 
applicable EM's.

    (f) This amendment becomes effective on April 16, 2002.

    Issued in Burlington, Massachusetts, on February 5, 2002.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 02-3579 Filed 2-14-02; 8:45 am]
BILLING CODE 4910-13-U