[Federal Register Volume 70, Number 250 (Friday, December 30, 2005)]
[Proposed Rules]
[Pages 77342-77345]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E5-8099]


 ========================================================================
 Proposed Rules
                                                 Federal Register
 ________________________________________________________________________
 
 This section of the FEDERAL REGISTER contains notices to the public of 
 the proposed issuance of rules and regulations. The purpose of these 
 notices is to give interested persons an opportunity to participate in 
 the rule making prior to the adoption of the final rules.
 
 ========================================================================
 

  Federal Register / Vol. 70, No. 250 / Friday, December 30, 2005 / 
Proposed Rules  

[[Page 77342]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2001-NE-30-AD]
RIN 2120-AA64


Airworthiness Directives; Pratt & Whitney JT8D-1, -1A, -1B, -7, -
7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -17R, -17AR, -209, -217, -
217A, -217C, and -219 Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for Pratt & Whitney (PW) JT8D-209, -217, -217A, -217C, 
and -219 turbofan engines. That AD currently requires initial and 
repetitive visual inspections for fretting and fluorescent magnetic 
particle inspections (FMPI) for cracking in the area of the tierod 
holes on 8th stage high pressure compressor (HPC) front hubs (from here 
on, referred to as HPC front hubs) that have operated at any time with 
PWA 110-21 coating. This proposed AD would require either replacing HPC 
front hubs and HPC disks that have operated at any time with PWA 110-21 
coating and that operated in certain engine models, or, visually 
inspecting and FMPI for cracking of those parts and replating them if 
they pass inspection. This proposed AD would also require adding JT8D-
1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, 17A, 17R, and 
17AR engines to the applicability. This proposed AD results from an 
investigation by PW, which concluded that any HPC front hub or HPC disk 
coated with PWA 110-21 that ever operated on JT8D-15, -15A, -17, -17A, 
-17R, -17AR, -209, -217, -217A, -217C, and -219 turbofan engines, could 
crack before reaching their published life limit. We are proposing this 
AD to prevent a rupture of an HPC front hub or an HPC disk that could 
result in an uncontained engine failure and damage to the airplane.

DATES: We must receive any comments on this proposed AD by February 28, 
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. 2001 NE-30-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
     By fax: (781) 238-7055.
     By e-mail: [email protected].
    Contact Pratt & Whitney, 400 Main St., East Hartford, CT 06108, 
telephone (860) 565-7700; fax (860) 565-1605 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: Keith Lardie, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803-5299; telephone (781) 
238-7189; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2001-NE-30-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.

Examining the AD Docket

    You may examine the docket that contains the proposal, any comments 
received and any final disposition by appointment, between 8 a.m. and 
4:30 p.m., Monday through Friday, except Federal holidays. See 
ADDRESSES for the location.

Discussion

    On November 15, 2002, we issued AD 2002-23-14, Amendment 39-12958 
(67 FR 70686, November 26, 2002). That AD requires initial and 
repetitive visual inspections for fretting and FMPI for cracking in the 
area of the tierod holes on HPC front hubs that have operated at any 
time with PWA 110-21 coating. That AD resulted from the discovery of 
cracking in the area of the tierod holes, found during routine engine 
overhauls. That condition, if not corrected, could result in an 
uncontained engine failure and damage to the airplane.

Actions After We Issued AD 2002-23-14

    After we issued AD 2002-23-14, PW completed their investigation to 
determine the cause of cracking in the area of the tierod holes on HPC 
front hubs. As part of that investigation, PW looked at seven HPC front 
hubs coated with PWA 110-21. They found fretting, cracks, or both, at 
the rear bolt face of the HPC front hub on six of the seven HPC front 
hubs. This was similar to the cracks seen in PW's initial investigation 
into this issue. Most of the seven hubs had low cycle time, with the 
lowest being 2,800 cycles-since-new. Additional cracks were found on 
other stages of HPC disks, both with nickel-cadmium, and PWA 110-21 
coating. PW determined that all HPC front hubs and HPC disks that have 
ever been coated with PWA 110-21 and that have ever been operated on 
JT8D-15, -15A, -17, -17A, -17R, -17AR, -209, -217, -217A, -217C, and -
219 turbofan engines, have a higher risk of fracturing before reaching 
their published life limit of 20,000 cycles-in-service, than HPC front 
hubs and HPC disks plated with nickel-cadmium.

Relevant Service Information

    We have reviewed and approved the technical contents of PW Alert 
Service Bulletin (ASB) No. JT8D A6430, Revision 2, dated December 23, 
2004, applicable to JT8D-209, -217, -217A,

[[Page 77343]]

-217C, and -219 turbofan engines, and PW ASB No. JT8D A6468, dated 
December 23, 2004, applicable to JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -
9A, -11, -15, -15A, -17, -17A, -17R, and -17AR turbofan engines. Those 
ASBs describe procedures for visual inspections for fretting wear and 
FMPI for cracking of HPC front hubs that have operated with PWA 110-21 
coating in the interface between the HPC front hub and the stage 8-9 
spacer. Those ASBs also describe procedures for replating HPC front 
hubs using nickel-cadmium, and replating stage 8-9 spacers using 
nickel-cadmium or electroless nickel.

Differences Between the Proposed AD and the Manufacturer's Service 
Information

    Although the ASBs only require inspection of the HPC front hubs and 
stage 8-9 spacers, we propose to require inspecting all 7th stage HPC 
disks and 9th stage-through-12th stage HPC disks for fretting wear and 
FMPI for cracking at the same time the HPC front hub is visually 
inspected. These other HPC disks, which are coated with PWA 110-21, 
have increased risk of cracking and failure.

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:
     Visual inspections for fretting wear and FMPI of HPC front 
hubs, HPC disks, and stage 8-9 spacers that at any time operated coated 
with PWA 110-21, replacing them if necessary; replating those HPC front 
hubs and disks using nickel-cadmium, and replating stage 8-9 spacers 
using nickel-cadmium or electroless nickel;
    OR
     As optional terminating action to the visual inspections 
in the proposed AD, replacing HPC front hubs, HPC disks, and stage 8-9 
spacers that at any time operated coated with PWA 110-21 in JT8D-15, -
15A, -17, -17A, -17R, -17AR, -209, -217, -217A, -217C, or -219 turbofan 
engines.
     Replacement must be with HPC front hubs and HPC disks 
plated with nickel-cadmium that have never operated with PWA 110-21 
coating, and stage 8-9 spacers plated with nickel-cadmium or 
electroless nickel.
    The proposed AD would require that you do these actions using the 
service information described previously.

Costs of Compliance

    About 1,573 JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -
15A, -17, -17A, -17R, and -17AR turbofan engines, and 1,280 JT8D-200 
series turbofan engines, installed on airplanes of U.S. registry would 
be affected by this proposed AD. We estimate it would take about 12 
work hours per engine to perform the proposed actions, and the average 
labor rate is $65 per work hour. We also estimate 175 of those engines 
would be removed before reaching scheduled maintenance, and would 
require an additional 60 work hours to disassemble and reassemble each 
engine. Based on these figures, we estimate the total cost of the 
proposed AD to U.S. operators to be $2,907,840.

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 110-2134, 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. 2001-NE-30-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 39-12958 (67 FR 
70686, November 26, 2002) and by adding a new airworthiness directive 
to read as follows:

Pratt & Whitney: Docket No. 2001-NE-30-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by February 28, 
2006.

Affected ADs

    (b) This AD supersedes AD 2002-23-14, Amendment 39-12958.

Applicability

    (c) This AD applies to all Pratt & Whitney (PW) JT8D-1, -1A, -
1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -17R, -17AR, -
209, -217, -217A, -217C, and -219 turbofan engines, with 8th stage 
high pressure compressor (HPC) front hubs (from here on, referred to 
as HPC front hubs) as defined in the following Table 1:

                       Table 1.--AD Applicability
------------------------------------------------------------------------
                                And the HPC front hub:  Then this AD is:
              If:
------------------------------------------------------------------------
(1) The HPC front hub at any    Operated in a JT8D-15,  Applicable.
 time operated coated with PWA   -15A, -17, -17R, -
 110-21.                         17AR, -209, -217, -
                                 217A, -217C, or -219
                                 engine.

[[Page 77344]]

 
(2) The HPC front hub at any    Operated in a JT8D-     Applicable.
 time had coating in the         209, -217, -217A, -
 interface between the HPC       217C, or -219 engine.
 front hub and the stage 8-9
 spacer (PWA 110-21 coating
 applied to spacer).
(3) The HPC front hub and HPC   Operated in a JT8D-1, - Not applicable.
 disks have PWA 110-21           1A, -1B, -7, -7A, -
 coating.                        7B, -9, -9A, or -11
                                 engine, but never
                                 operated in a JT8D-
                                 15, -15A, -17, -17A, -
                                 17R, -17AR, -209, -
                                 217, -217A, -217C, or
                                 -219 engine.
(4) The HPC front hub has       ......................  Not applicable.
 never operated with PWA 110-
 21 coating in the interface
 with the stage 8-9 spacer,
 either on the HPC front hub
 or on the stage 8-9 spacer.
------------------------------------------------------------------------

    These engines are installed on, but not limited to, Boeing DC-9, 
MD-80 series, 727 series, and 737 series airplanes.

Unsafe Condition

    (d) This AD results from an investigation by PW, which concluded 
that any HPC front hub or HPC disk coated with PWA 110-21 that ever 
operated on JT8D-15, -15A, -17, -17A, -17R, -17AR, -209, -217, -
217A, -217C, and -219 turbofan engines, could crack before reaching 
their published life limit. We are issuing this AD to prevent a 
rupture of an HPC front hub or an HPC disk that could result in an 
uncontained engine failure and 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.

JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -
17R, and -17AR Turbofan Engines--Inspect or Replace HPC Front Hubs, HPC 
Disks, and Stage 8-9 Spacers

    (f) For JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, 
-17, -17A, -17R, and -17AR turbofan engines, do the following:
    (1) Using the inspection schedule in Table 2 of this AD, strip 
the protective coating, visually inspect for fretting wear, 
fluorescent magnetic particle inspect (FMPI) for cracks, reidentify, 
replate HPC front hubs and stage 8-9 spacers, and replace if 
necessary.
    (2) Use paragraphs 1 through 3.B.(7)(b) under ``For Rear 
Compressor Front Hubs that Have Operated With PWA 110-21 coating AT 
ANY TIME During Their Service Life in JT8D-15, -15A, -17, -17A, -
17R, -17AR Engine Models.'' of PW Alert Service Bulletin (ASB) JT8D 
A6468, dated December 23, 2004.

                 Table 2.--HPC Disk Inspection Schedule
------------------------------------------------------------------------
                                    Inspect before     Also inspect 7th
 HPC front hub cycles-since-new   additional cycles-    stage HPC disks
 (CSN) on the effective date of    in-service (CIS)     and 9th stage-
             this AD               or CSN, whichever  through-12th stage
                                     occurs first      HPC disks using:
------------------------------------------------------------------------
(i) 19,000 or more                500 CIS or 20,000   Paragraph (f)(3)
                                   CSN                 of this AD
(ii) 15,500 or more, but fewer    1,000 CIS or        Paragraph (f)(3)
 than 19,000.                      19,500 CSN.         of this AD.
(iii) Fewer than 15,500.          5,000 CIS or        Paragraph (f)(3)
                                   16,500 CSN.         of this AD.
(iv) Fewer than 5,000 that are    ..................  Paragraph (f)(3)
 accessible.                                           of this AD. If
                                                       the parts pass
                                                       inspection, parts
                                                       may be
                                                       reinstalled.
                                                       Inspect again
                                                       using the
                                                       criteria listed
                                                       in (iii) of this
                                                       Table.
------------------------------------------------------------------------

    (3) When the HPC front hub is inspected, visually inspect for 
fretting wear and FMPI for cracks on 7th stage HPC disks and 9th 
stage-through-12th stage HPC disks. Inspection information can be 
found in the applicable sections of JT8D Engine Manual Part Number 
(P/N) 481672, listed in the following Table 3:

Table 3.--7th Stage HPC Disks and 9th Stage-Through-12th Stage HPC Disks
                         Inspection Information
------------------------------------------------------------------------
          Chapter/        Visual           Fretting
 Stage    Section       inspection        inspection           FMPI
------------------------------------------------------------------------
7.....     72-36-41  Inspection-01...  Inspection-04...  Inspection-03.
9.....     72-36-43  Inspection-01...  Inspection-04...  Inspection-03.
10....     72-36-44  Inspection-01...  Inspection-04...  Inspection-03.
11....     72-36-45  Inspection-01...  Inspection-04...  Inspection-03.
12....     72-36-46  Inspection-01...  Inspection-04...  Inspection-03.
------------------------------------------------------------------------

JT8D-15, -15A, -17, -17A, -7R, and -17AR Turbofan Engines--Cycle 
Adjustment for HPC Front Hubs That Entered Service With Nickel-Cadmium 
Plating and PWA 110-21 Coating

    (g) For JT8D-15, -15A, -17, -17A, -17R, and -17AR turbofan 
engines with front hubs that entered service with nickel-cadmium 
plating and PWA 110-21 coating, but have also operated during the 
life of the hub with PWA 110-21 coating:
    (1) You are allowed to make a cycle adjustment if the hub was 
never operated with a PWA 110-21-coated stage 8-9 spacer.
    (2) Use the information under ``Compliance'' of PW ASB JT8D 
A6468, dated December 23, 2004, to determine the adjustment.

JT8D-209, -217, -217A, -217C, and -219 Turbofan Engines--Inspect or 
Replace HPC Front Hubs and Stage 8-9 Spacers

    (h) For JT8D-209, -217, -217A, -217C, and -219 turbofan engines, 
do the following:

[[Page 77345]]

    (1) Using the inspection schedule in Table 4 of this AD, strip 
the protective coating, visually inspect for fretting wear, FMPI for 
cracking, reidentify, replate HPC front hubs and the stage 8-9 
spacers, and replace if necessary.
    (2) Use paragraphs 1. through 1.A. and paragraphs 2 through 
2.C.(2)(g)2 of Accomplishment Instructions of PW ASB JT8D A6430, 
Revision 2, dated December 23, 2004.

                 Table 4.--HPC Disk Inspection Schedule
------------------------------------------------------------------------
                                                       Also inspect 7th
                                    Inspect before      stage HPC disks
    HPC front hub CSN on the       additional CIS or    and 9th stage-
    effective date of this AD       CSN, whichever    through-12th stage
                                     occurs first      HPC disks using:
------------------------------------------------------------------------
(i) 19,000 or more..............  500 CIS or 20,000   Paragraph (h)(3)
                                   CSN.                of this AD.
(ii) 15,500 or more, but fewer    1,000 CIS or        Paragraph (h)(3)
 than 19,000.                      19,500 CSN.         of this AD.
(iii) Fewer than 15,500.........  5,000 CIS or        Paragraph (h)(3)
                                   16,500 CSN.         of this AD.
(iv) Fewer than 5,000 that are    ..................  Paragraph (h)(3)
 accessible.                                           of this AD. If
                                                       the parts pass
                                                       inspection, parts
                                                       may be
                                                       reinstalled.
                                                       Inspect again
                                                       using the
                                                       criteria listed
                                                       in (iii) of this
                                                       Table.
------------------------------------------------------------------------

    (3) When the HPC front hub is inspected, visually inspect for 
fretting wear and FMPI for cracks on 7th stage HPC disks and 9th 
stage through 12th stage HPC disks. Inspection information can be 
found in the applicable sections of JT8D-200 Engine Manual P/N 
773128, listed in Table 3 of this AD.

JT8D-209, -217, -217A, -217C, and -219 Turbofan Engines--Cycle 
Adjustment for HPC Front Hubs That Entered Service With Nickel-Cadmium 
Plating and PWA 110-21 Coating

    (i) For JT8D-209, -217, -217A, -217C, and -219 turbofan engines 
with HPC front hubs that entered service with nickel-cadmium 
plating, but have also operated during the life of the hub with PWA 
110-21 coating:
    (1) You are allowed to make a cycle adjustment.
    (2) Use the information under ``CONDITION A'' of PW ASB JT8D 
A6430, Revision 2, dated December 23, 2004, to determine the 
adjustment.

Replacement of HPC Front Hubs and Stage 8-9 Spacers That Have Operated 
With PWA 110-21 Coating, As Optional Terminating Action--All Engines

    (j) For all applicable engines, as optional terminating action 
for the repetitive visual inspections in this AD, replace HPC front 
hubs and stage 8-9 spacers that have operated with PWA 110-21 
coating in the interface between the hub and the stage 8-9 spacer 
and HPC disks currently coated with PWA 110-21, as follows:
    (1) Install a nickel-cadmium plated HPC front hub that has never 
operated with PWA 110-21 coating in the interface between the HPC 
front hub and the stage 8-9 spacer.
    (2) Install a nickel-cadmium plated or electroless nickel-plated 
stage 8-9 spacer.
    (3) Install HPC disks that have never operated with PWA 110-21 
coating.

Prohibition Against Recoating the HPC Front Hub, Stage 7 HPC Disk, and 
Stage 8-9 Spacer With PWA 110-21--All Engines

    (k) Do not recoat the HPC front hub with PWA 110-21 (Repair-23 
of Chapter/Section 72-36-42 of JT8D-200 Engine Manual, P/N 773128, 
and Repair-27 and Repair-28 of Chapter/Section 72-36-42 of JT8D 
Engine Manual, P/N 481672).
    (l) Do not recoat the 7th stage disk with PWA 110-21 (Repair-15 
of Chapter/Section 72-36-41 of JT8D-200 Engine Manual, P/N 773128, 
and Repair-15 of Chapter/Section 72-36-41 of JT8D Engine Manual, P/N 
481672).
    (m) Do not recoat the stage 8-9 spacer with PWA 110-21 (Repair-
03, Task 72-36-12-30-003-002, of Chapter/Section 72-36-12 of JT8D-
200 Engine Manual, P/N 773128, and Repair-01, Task 72-36-12-30-001-
002, of Chapter/Section 72-36-12 of JT8D Engine Manual, P/N 481672).

Definitions

    (n) For the purposes of this AD, a shop visit is an engine 
removal, where engine maintenance entails separating pairs of major 
engine flanges or removing a disk, hub, or spool at a maintenance 
facility, regardless of other planned maintenance, except as 
follows:
    (1) Removing the engine to perform field maintenance type 
activities at a maintenance facility in lieu of performing them on-
wing is not a ``shop visit.''
    (2) Separating flanges of the Combustion Chamber and Turbine Fan 
Duct Assembly (split flanges) to access non-rotating accessory 
hardware is not a ``shop visit.''
    (3) Separating flanges to ship the engine without subsequent 
internal maintenance is not a ``shop visit.''
    (o) For the purposes of this AD accessibility of the HPC front 
hub is removing the hub from the engine and deblading that hub.

Alternative Methods of Compliance

    (p) 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

    (q) None.

    Issued in Burlington, Massachusetts, on December 23, 2005.
Carlos Pestana,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E5-8099 Filed 12-29-05; 8:45 am]
BILLING CODE 4910-13-P