[Federal Register Volume 70, Number 211 (Wednesday, November 2, 2005)]
[Proposed Rules]
[Pages 66302-66305]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-21802]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 92-ANE-34-AD]
RIN 2120-AA64


Airworthiness Directives; Honeywell International Inc., (Formerly 
AlliedSignal, Inc. and Textron Lycoming) ALF502L Series and ALF502R 
Series 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), AD 95-04-11, for Honeywell International Inc., 
(formerly AlliedSignal, Inc. and Textron Lycoming) ALF502L series and 
ALF502R series turbofan engines. That AD currently establishes stress 
rupture retirement life limits for certain third stage turbine discs 
used in conjunction with certain third stage turbine nozzles. This 
proposed AD would bring requirements forward and unchanged, from the 
previous AD for ALF502R series turbofan engines. Also, this proposed AD 
would establish new reduced stress rupture retirement life limits for 
certain part numbers (P/Ns) of third stage turbine disc and shaft 
assemblies installed in ALF502L series turbofan engines. This proposed 
AD would also require removing those same parts from service using a 
drawdown schedule. This proposed AD results from a report of failure of 
a third stage turbine disc and shaft assembly, leading to turbine blade 
release and separation of the exhaust nozzle. We are proposing this AD 
to prevent total loss of engine power, in-flight engine shutdown, 
release of turbine blades, separation of the exhaust nozzle, and 
possible damage to the airplane.

DATES: We must receive any comments on this proposed AD by January 3, 
2006.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD:
     By mail: Federal Aviation Administration (FAA), New 
England Region, Office of the Regional Counsel, Attention: Rules Docket 
No. 92-ANE-34-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
     By fax: (781) 238-7055.
     By e-mail: [email protected].
    Contact Honeywell Engines, Systems & Services, Customer Support 
Center, M/S 26-06/2102-323, P.O. Box 29003, Phoenix, AZ 85038-9003; 
telephone (800) 601-3099, for the service information identified in 
this proposed AD.
    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: Robert Baitoo, Aerospace Engineer, Los 
Angeles Aircraft Certification Office, FAA, Transport Airplane 
Directorate, 3960 Paramount Blvd., Lakewood, CA 90712-4137; telephone: 
(562) 627-5245, fax: (562) 627-5210.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 92-ANE-34-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

[[Page 66303]]

the closing date and may amend the proposed AD in light of those 
comments.

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 March 2, 1995, we issued AD 95-04-11, Amendment 39-9163 (60 FR 
11621, April 3, 1995), applicable to ALF502L series and ALF502R series 
turbofan engines. That AD established stress rupture retirement life 
limits for certain third stage turbine discs used in conjunction with 
certain third stage turbine nozzles. That AD resulted from introduction 
of an improved design third stage turbine nozzle, and a new reduced 
stress rupture retirement life limit for certain third stage turbine 
discs on the ALF502L series engines. That condition, if not corrected, 
could result in total loss of engine power, in-flight engine shutdown, 
and possible damage to the airplane.

Actions Since AD 95-04-11 Was Issued

    Since we issued that AD, we received a report of a third stage 
turbine disc and shaft assembly failure in an ALF502L-2C engine. The 
rim of the disc ruptured during airplane climb, resulting in release of 
turbine blades and separation of the exhaust nozzle. Honeywell 
International Inc. has also cited several other separation incidents of 
third stage turbine blades, resulting in airplane and engine damage. 
The third stage turbine disc and shaft assemblies involved in these 
events were all of the Honeywell Pre SB No. ALF502L 72-232 
configuration.

Relevant Service Information

    We have reviewed and approved the technical contents of Honeywell 
International Service Bulletin (SB) No. ALF502 72-0004, Revision 17, 
dated January 16, 2005. That SB establishes new reduced service life 
limits for third stage turbine disc and shaft assemblies installed in 
ALF502L series turbofan engines that have operated in the Pre SB No. 
ALF502L 72-232 configuration. That SB also describes procedures for 
calculating the remaining service life of certain third stage turbine 
disc and shaft assemblies that have operated in Pre and Post SB No. 
ALF502L 72-232 configurations.

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. We are proposing this AD, which would 
require:
     Bringing requirements forward and unchanged from AD 95-04-
11 for ALF502R series turbofan engines; and
     For ALF502L series turbofan engines, establishing new 
reduced service life limits for third stage turbine disc and shaft 
assemblies, P/N 2-143-030-05; P/N 2-143-030-08; P/N 2-143-030-14; P/N 
2-143-030-R21; P/N 2-143-030-22; and P/N 2-143-030-23, that have 
operated in the Honeywell Pre SB No. ALF502L 72-232 configuration; and
     Removing those same parts from service using a drawdown 
schedule.
     Limiting the special flight permits for this AD by 
allowing a onetime special flight if the disc life limit has been 
reached.
The proposed AD would require that you calculate the remaining service 
life of certain third stage turbine disc and shaft assemblies using the 
service information described previously.

Costs of Compliance

    There are about 180 Honeywell International, Inc. ALF502L, ALF502L-
2, ALF502L-2A, ALF502L-2C, ALF502L-3, and ALF502R series turbofan 
engines of the affected design in the worldwide fleet. We estimate the 
proposed AD would affect 170 engines installed on airplanes of U.S. 
registry. We also estimate that it would take about 14 work hours per 
engine to perform the proposed actions, and that the average labor rate 
is $65 per work hour. The prorated cost of a replacement third stage 
turbine disc and shaft assembly is estimated to be $40,000. Based on 
these figures, we estimate the total labor cost of the proposed AD on 
U.S. operators to be $6,954,700.

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

    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. 92-ANE-34-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 39-9163 (60 FR 
11621, April 3, 1995) and by adding a new airworthiness directive to 
read as follows:

Honeywell International Inc. (formerly AlliedSignal, Inc. and 
Textron Lycoming): Docket No. 92-ANE-34-AD.

[[Page 66304]]

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by January 3, 
2006.

Affected ADs

    (b) This AD supersedes AD 95-04-11, Amendment 39-9163.

Applicability

    (c) This AD applies to Honeywell International Inc., (formerly 
AlliedSignal, Inc. and Textron Lycoming) ALF502L, ALF502L-2, 
ALF502L-2A, ALF502L-2C, and ALF502L-3 series turbofan engines with 
third stage turbine disc and shaft assemblies that have operated in 
the Honeywell Pre SB No. ALF502L 72-232 configuration. This AD also 
applies to ALF502R series engines. These engines are installed on, 
but not limited to, BAe Systems AVRO 146 and Bombardier (Canadair) 
CL600-1A11 series airplanes.

Unsafe Condition

    (d) This AD results from a report of failure of a third stage 
turbine disc and shaft assembly, leading to turbine blade release 
and separation of the exhaust nozzle. We are issuing this AD to 
prevent total loss of engine power, in-flight engine shutdown, 
release of turbine blades, separation of the exhaust nozzle, and 
possible damage to the airplane.

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.

ALF502L Series Turbofan Engines

Determination of Third Stage Turbine Disc and Shaft Assembly 
Drawdown Schedule

    (f) For ALF502L series turbofan engines, determine if the third 
stage turbine disc and shaft assembly is currently operating in the 
Pre SB No. ALF502L 72-232 configuration as follows:
    (1) If third stage turbine nozzle assembly, part number (P/N) 2-
141-120R56/-57 is installed, then Honeywell SB No. ALF502L 72-232 
has been complied with. Proceed to the drawdown schedule in 
paragraph (h) of this AD.
    (2) If any other third stage turbine nozzle assembly is 
installed, then the engine is in the Pre SB No. ALF502L 72-232 
configuration. Proceed to the drawdown schedule in paragraph (g) of 
this AD.

Drawdown Schedule for Third Stage Turbine Disc and Shaft Assemblies 
That Are Operating in the Pre SB No. ALF502L 72-232 Configuration

    (g) For ALF502L series turbofan engines, use the drawdown 
schedule described in the following Table 1, and replace with 
serviceable parts:

   Table 1.--Drawdown Schedule for Third Stage Turbine Disc and Shaft
            Assemblies In Pre SB ALF502L 72-232 Configuration
------------------------------------------------------------------------
                               If hours-in-service
For third stage turbine disc      (HIS) on the
   and shaft assembly P/Ns      effective date of        Then remove
                                   this AD are
------------------------------------------------------------------------
2-143-030-05................  (1) 5,200 or more     Within 50 additional
                               HIS.                  HIS.
2-143-030-08................  (2) 5,001 to 5,199    Before reaching
                               HIS.                  5,250 HIS.
2-143-030-14................  (3) 2,551 to 5,000    Within 250
                               HIS.                  additional HIS.
2-143-030R21................  (4) 2,550 or fewer    Before reaching
                               HIS.                  2,800 HIS.
2-143-030-22................
2-143-030-23................
------------------------------------------------------------------------

Determination of Drawdown Schedule for Third Stage Turbine Disc and 
Shaft Assemblies That Have Operated in Pre and Post SB No. ALF502L 72-
232 Configurations

    (h) For ALF502L series turbofan engines, with third stage 
turbine disc and shaft assemblies converted from Pre SB No. ALF502L 
72-232 configuration to Post SB No. ALF502L 72-232 configuration, do 
the following:
    (1) Determine the total HIS accumulated on the third stage 
turbine disc and shaft assembly at time of installation of third 
stage turbine nozzle assembly, P/N 2-141-120-R56/-57.
    (2) If the total is 2,800 HIS or more, use the drawdown schedule 
in Table 1 of this AD to remove the assembly from service.
    (3) If the total is fewer than 2,800 HIS, calculate the 
remaining service life using paragraphs 2.A. through 2.B.(4)(i) of 
the Accomplishment Instructions of Honeywell SB No. ALF502 72-0004, 
Revision 17, dated January 16, 2005.
    (i) For ALF502L series turbofan engines, use the drawdown 
schedule described in the following Table 2 to remove the assembly 
from service:

   Table 2.--Drawdown Schedule for Third Stage Turbine Disc and Shaft
 Assemblies Operated In Pre and Post SB No. ALF502L 72-232 Configuration
------------------------------------------------------------------------
For third stage turbine disc      If HIS on the
   and shaft assembly part      effective date of           Then:
          numbers:                this AD are:
------------------------------------------------------------------------
(1) 2-143-030-05, 2-143-030-  (i) 30,000 or more    Remove within 50
 08,2-143-030-14.              HIS.                  additional HIS.
                              (ii) 27,250 to        Remove within 250
                               29,999 HIS.           additional HIS.
                              (iii) Fewer than 27,  Remove using Tables
                               250 HIS.              1 through 5 of
                                                     Honeywell SB No.
                                                     ALF502 72-0004,
                                                     Revision 17, dated
                                                     January 16, 2005.
(2) 2-143-030R21, 2-143-030-  (i) 24,650 or more    Remove within 50
 23.                           HIS.                  additional HIS.
                              (ii) 22,150 to        Remove within 250
                               24,649 HIS.           additional HIS.
                              (iii) Fewer than      Remove using Tables
                               22,150 HIS.           1 through 5 of
                                                     Honeywell SB No.
                                                     ALF502 72-0004,
                                                     Revision 17, dated
                                                     January 16, 2005.
(3) 2-143-030-22............  (i) 50,000 or more    Remove within 50
                               HIS.                  additional HIS.
                              (ii) 49,750 to        Remove within 250
                               49,999 HIS.           additional HIS.
                              (iii) Fewer than      Remove using Tables
                               49,750 HIS.           1 through 5 of
                                                     Honeywell SB No.
                                                     ALF502 72-0004,
                                                     Revision 17, dated
                                                     January 16, 2005.
------------------------------------------------------------------------


[[Page 66305]]

ALF502R Series Turbofan Engines

Requirements Brought Forward, and Unchanged From AD 95-04-11

    (j) For ALF502R series turbofan engines, remove from service and 
replace with a serviceable part third stage turbine disks, P/Ns 2-
143-030-05, 2-143-030-08, and 2-143-030-14, as follows:
    (1) For disks that have been installed only with third stage 
turbine nozzles P/Ns 2-141-130-52 or 2-141-120-53, remove from 
service as follows:
    (i) For disks that have accumulated 13,220 or more hours time in 
service (TIS) since new on April 13, 1995 (the effective date of AD 
95-04-11), within the next 80 hours TIS after December 11, 1990, but 
not to exceed the existing cyclic life limit.
    (ii) For disks that have accumulated less than 13,220 hours TIS 
since new on April 13, 1995, before accumulating more than 13,300 
hours TIS since new, but not to exceed the existing cyclic life 
limit.
    (iii) Thereafter, remove disks before accumulating more than 
13,300 hours TIS since new, but not to exceed the existing cyclic 
life limit.
    (2) For disks that have been installed only with third stage 
turbine nozzles, P/Ns 2-141-120-57 or 2-141-120-R56, remove from 
service as follows:
    (i) For disks that have accumulated 27,420 or more hours TIS 
since new on April 13, 1995, within 80 hours TIS after April 13, 
1995, but not to exceed the existing cyclic life limit.
    (ii) For disks that have accumulated less than 27,420 hours TIS 
since new on April 13, 1995, before accumulating more than 27,500 
hours TIS since new, but not to exceed the existing cyclic life 
limit.
    (iii) Thereafter, remove disks before accumulating more than 
27,500 hours TIS since new, but not to exceed the existing cyclic 
life limit.
    (3) For disks that have been installed with both third stage 
turbine nozzles, P/Ns 2-141-120-52 or 2-141-120-120-53, and third 
stage turbine nozzles P/Ns 2-141-120-57 or 2-141-120-R56, remove 
from service as follows:
    (i) Determine the prorated hourly life limit using the procedure 
defined in the Accomplishment Instructions, Section 2.B.(2) of 
Textron Lycoming SB No. ALF502 72-0002, Revision 22, dated December 
21, 1992. From this prorated hourly life limit, subtract 80 hours 
TIS to determine the compliance threshold.
    (ii) For disks that have equaled or exceeded the compliance 
threshold on April 13, 1995, within the next 80 hours TIS, but not 
to exceed the existing cyclic life limit.
    (iii) For disks that have accumulated fewer than the compliance 
threshold on April 13, 1995, before accumulating more than the 
calculated prorated hourly life limit.
    (iv) Thereafter, remove disks at or before accumulating the 
prorated hourly life limit, but not to exceed the existing cyclic 
life limit.

Alternative Methods of Compliance

    (k) The Manager, Los Angeles Aircraft 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.

Special Flight Permits

    (l) Under 14 CFR part 39.23, we are limiting the special flight 
permits for this AD by allowing a onetime special flight if the disc 
life limit has been reached.

Related Information

    (m) Honeywell SB No. ALF/LF A72-1085, Revision 1, dated January 
16, 2005, pertains to the subject of this AD.

    Issued in Burlington, Massachusetts, on October 27, 2005.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-21802 Filed 11-1-05; 8:45 am]
BILLING CODE 4910-13-P