[Federal Register Volume 68, Number 180 (Wednesday, September 17, 2003)]
[Proposed Rules]
[Pages 54400-54401]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-23674]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2003-NE-21-AD]
RIN 2120-AA64


Airworthiness Directives; International Aero Engines AG (IAE) 
V2522-A5, V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and 
V2533-A5 Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for certain IAE V2522-A5, V2524-A5, V2527-A5, V2527E-A5, 
V2527M-A5, V2530-A5, and V2533-A5 turbofan engines. That AD currently 
requires initial and repetitive inspections of the master magnetic chip 
detector (MCD) or the No. 1, 2, 3 bearing chamber MCD. This proposed AD 
would require the MCD inspections, and would require replacing certain 
No. 3 bearings and replacing or recoating certain high pressure 
compressor (HPC) stubshaft assemblies as mandatory terminating actions 
to the repetitive MCD inspections. This proposed AD is prompted by the 
development of a terminating action to the repetitive MCD inspections. 
We are proposing this AD to prevent failure of the No. 3 bearing, which 
could result in in-flight shutdown (IFSD) and smoke in the cockpit and 
cabin.

DATES: We must receive any comments on this proposed AD by November 17, 
2003.

ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD:
    [sbull] By mail: Federal Aviation Administration (FAA), New England 
Region, Office of the Regional Counsel, Attention: Rules Docket No. 
2003-NE-21-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
    [sbull] By fax: (781) 238-7055.
    [sbull] By e-mail: [email protected].
    You can get the service information identified in this proposed AD 
from International Aero Engines AG, 400 Main Street, East Hartford, CT 
06108; telephone: (860) 565-5515; fax: (860) 565-5510.
    You may examine the AD docket at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA.

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) 238-7152; 
fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to submit any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2003-NE-21-AD'' in the 
subject line of your comments. If you want us to acknowledge receipt of 
your mailed comments, send us a self-addressed, stamped postcard with 
the docket number written on it; we will date-stamp your postcard and 
mail it back to you. We specifically invite comments on the overall 
regulatory, economic, environmental, and energy aspects of the proposed 
AD. If a person contacts us verbally, and that contact relates to a 
substantive part of this proposed AD, we will summarize the contact and 
place the summary in the docket. We will consider all comments received 
by the closing date and may amend the proposed AD in light of those 
comments.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications that affect you. You may get more information about 
plain language at http://www.faa.gov/language and http://www.plainlanguage.gov.

Examining the AD Docket

    You may examine the AD Docket (including any comments and service 
information), by appointment, between 8 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. See ADDRESSES for the 
location.

Discussion

    On May 29, 2003, the FAA issued AD 2003-11-23, Amendment 39-13183 
(68 FR 33621, June 5, 2003). That AD requires initial and repetitive 
inspections of the master MCD or the No. 1, 2, 3 bearing chamber MCD 
for contamination, and if the contamination is bearing material, 
replacement of the engine before further flight. That AD was prompted 
by 19 failures of the No. 3 bearing attributed to ball spalling and 
race fracture. Of the 19 failures, seven resulted in in-flight 
shutdowns (IFSDs) and 12 resulted in unscheduled engine removals 
(UERs). Of the seven IFSDs, two were associated with smoke in the cabin 
or cockpit. The smoke is a result of the ball spalling and race 
fracture of failed No. 3 bearings, P/N 2A1165, and occurs when there is 
hard particle contamination in the oil system. The contamination is 
caused by the release of coating particles on HPC stubshafts with low-
energy plasma coating. The problem exists on certain No. 3 bearings, P/
N 2A1165 that are less tolerant to damage from this contamination. This 
AD is prompted by the addition of a mandatory terminating action to the 
repetitive chip detector inspections. That condition, if not corrected, 
could result in failure of the No. 3 bearing, which could result in 
IFSD and smoke in the cockpit and cabin.

Actions Since AD 2003-11-23 Was Issued

    Since that AD was issued, IAE has issued Service Bulletin No. 
V2500-ENG-72-0459, dated June 27, 2003, that provides procedures for 
replacing certain No. 3 bearings, P/N 2A1165, and replacing or 
recoating certain HPC stubshafts that have a low-energy plasma coating 
with HPC stubshafts that have a high-energy plasma coating.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design. Therefore, we are proposing this AD, which 
would require:
    [sbull] Initial inspection of the master MCD and the No. 1, 2, 3 
bearing chamber MCD within 125 hours time-in-service (TIS) after the 
effective date of this AD,
    [sbull] Repetitive inspections of the master MCD and the No. 1, 2, 
3 bearing

[[Page 54401]]

chamber MCD within 125 hours time-since-last inspection,
    [sbull] Replacement of the No. 3 bearing, P/N 2A1165, at the next 
shop visit for any reason, and
    [sbull] Replacement of HPC stubshafts that have a low-energy plasma 
coating with HPC shafts that have a high-energy plasma coating or 
recoating with a high-energy plasma coating at the next shop visit for 
any reason.

Changes to 14 CFR Part 39--Effect on the Proposed AD

    On July 10, 2002, we published a new version of 14 CFR part 39 (67 
FR 47997, July 22, 2002), which governs the FAA's AD system. This 
regulation now includes material that relates to altered products, 
special flight permits, and alternative methods of compliance. This 
material previously was included in each individual AD. Since this 
material is included in 14 CFR part 39, we will not include it in 
future AD actions.

Costs of Compliance

    There are about 404 IAE V2522-A5, V2524-A5, V2527-A5, V2527E-A5, 
V2527M-A5, V2530-A5, and V2533-A5 turbofan engines of the affected 
design in the worldwide fleet. We estimate that 170 engines installed 
on airplanes of U.S. registry would be affected by this proposed AD. We 
also estimate that it would take approximately 150 work hours per 
engine to perform the proposed actions, and that the average labor rate 
is $65 per work hour. Required parts would cost about $32,000 per 
engine. Based on these figures, we estimate the total cost of the 
proposed AD to U.S. operators to be $7,097,500.

Regulatory Findings

    We have determined that this proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD 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.
    For the reasons discussed above, I certify that the 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. Would 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 proposal and 
placed it in the AD Docket. You may get a copy of this summary by 
sending a request to us at the address listed under ADDRESSES. Include 
``AD Docket No. 2003-NE-21-AD'' in your request.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the Federal Aviation Administration proposes to amend 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. The FAA amends Sec.  39.13 by removing Amendment 39-13183 (68 FR 
33621, June 5, 2003), and by adding a new airworthiness directive to 
read as follows:

International Aero Engines AG: Docket No. 2003-NE-21-AD. Supersedes 
AD 2003-11-23, Amendment 39-13183.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by November 17, 
2003.

Affected ADs

    (b) This AD supersedes AD 2003-11-23, Amendment 39-13183.

Applicability

    (c) This AD applies to International Aero Engines AG (IAE) 
V2522-A5, V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and 
V2533-A5 turbofan engines that have a serial number (SN) from V10600 
through V11250 inclusive. These engines are installed on, but not 
limited to, Airbus Industrie A319, A320, and A321 series airplanes.

Unsafe Condition

    (d) This AD was prompted by reports of No. 3 bearing failures 
that resulted in in-flight shutdown (IFSD) and smoke in the cockpit 
and cabin. We are issuing this AD to prevent failure of the No. 3 
bearing, which could result in IFSD and smoke in the cockpit or 
cabin.

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.

Inspection of the Master Magnetic Chip Detector (MCD) or the No. 1, 2, 
3 Bearing Chamber MCD

    (f) For engines that have a No. 3 bearing, part number (P/N) 
2A1165, installed, do the following:
    (1) Within 125 hours time-in-service (TIS) after the effective 
date of this AD, inspect the master MCD and the No. 1, 2, 3 bearing 
chamber MCD.
    (2) Thereafter, within 125 hours time-since-last inspection, 
inspect the master MCD and the No. 1, 2, 3 bearing chamber MCD.
    (3) If you find bearing material on the master MCD or No. 1, 2, 
3 bearing chamber MCD, replace the engine before further flight.

Replacement of No. 3 Bearing

    (g) For engines that have a SN from V10600 through V11250 
inclusive with No. 3 bearing, P/N 2A1165, installed, replace the No. 
3 bearing at the next shop visit for any reason.
    (h) After the effective date of this AD, do not install any No. 
3 bearing, P/N 2A1165, removed in paragraph (g) of this AD, into any 
engine.

Replacement or Rework of High-Pressure Compressor (HPC) Stubshaft

    (i) For engines that have a SN from V10600 through V11250 
inclusive, replace the HPC stubshaft with an HPC stubshaft that has 
a high-energy plasma coating or rework the HPC stubshaft to a high-
energy plasma coating at the next shop visit for any reason.

Terminating Action

    (j) Performing the requirements specified in paragraphs (g) and 
(i) of this AD is terminating action to the repetitive MCD 
inspections specified in paragraph (f)(1) through (f)(3) of this AD.

Alternative Methods of Compliance

    (k) 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.

Material Incorporated by Reference

    (l) None.

Related Information

    (m) You can find information on inspecting the master MCD and 
the No. 1, 2, 3 bearing chamber MCD in section 79-00-00-601 of the 
Aircraft Maintenance Manual. You can find information on replacing 
the No. 3 bearing and replacing or recoating the HPC stubshaft in 
IAE Service Bulletin No. V2500-ENG-72-0459, dated June 27, 2003.

    Issued in Burlington, Massachusetts, on September 11, 2003.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 03-23674 Filed 9-16-03; 8:45 am]
BILLING CODE 4910-13-P