[Federal Register Volume 71, Number 10 (Tuesday, January 17, 2006)]
[Proposed Rules]
[Pages 2491-2493]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E6-379]


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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, DOT.

ACTION: Supplemental notice of proposed rulemaking (SNPRM); reopening 
of comment period.

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SUMMARY: This notice revises an earlier proposed airworthiness 
directive (AD) that applies to certain IAE V2522-A5, V2524-A5, V2527-
A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 turbofan engines. That 
proposal would have required initial and repetitive inspections of the 
master magnetic chip detector (MCD) or the No. 1, 2, 3 bearing chamber 
MCD. That proposal would also have required 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. That proposal resulted from IAE developing 
a terminating action to the repetitive inspections of the chip 
detectors. This action revises the proposed rule by expanding its 
applicability to include additional serial-numbered engines with 
certain No. 3 bearings installed. We are proposing this AD to prevent 
failure of the No. 3 bearing, which could result in an in-flight 
shutdown (IFSD) and smoke in the cockpit and cabin.

DATES: We must receive comments by March 20, 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. 2003-NE-21-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
     By fax: (781) 238-7055.
     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, by appointment, at the FAA, New 
England

[[Page 2492]]

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 send 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.

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 September 11, 2003, we issued a proposal to amend part 39 of the 
Federal Aviation Regulations (14 CFR part 39) to add an airworthiness 
directive (AD) to apply to International Aero Engines AG IAE V2522-A5, 
V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 
turbofan engines. The Office of the Federal Register published that 
proposal as a notice of proposed rulemaking (NPRM) supersedure in the 
Federal Register on September 17, 2003 (68 FR 54400). That NPRM would 
have required initial and repetitive inspections of the master magnetic 
chip detector (MCD) or the No. 1, 2, 3 bearing chamber MCD. 
Additionally, it would have required replacing certain No. 3 bearings 
and replacing or recoating certain HPC stubshaft assemblies as 
mandatory terminating actions to the repetitive MCD inspections. That 
NPRM resulted from IAE developing a 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 an 
IFSD and smoke in the cockpit and cabin.
    Since we issued that NPRM, we have received reports that more 
engines experienced No. 3 bearing failures attributed to ball spalling 
and race fracture. A total of 55 failures of the No. 3 bearing have 
occurred. Of the 55 failures, 12 resulted in IFSDs and 43 resulted in 
unscheduled engine removals (UER). Of the 12 IFSDs, three were 
associated with smoke in the cabin and 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 release of coating particles on HPC stubshafts with low-
energy plasma coating causes the contamination. The problem exists on 
certain No. 3 bearings, P/N 2A1165, that are less tolerant to damage 
from this contamination. As a result of these failures, we have added 
additional serial-numbered engines to this Supplemental NPRM. Since 
this change expands the scope of the originally proposed rule, we 
determined that it is necessary to reopen the comment period to provide 
additional opportunity for public comment. Also, since we issued that 
NPRM, IAE discovered that some of the original population of engines 
are not at risk for No. 3 ball bearing failure, so even though we are 
adding at least 100 engine SNs to this proposed AD, the number of 
engines listed in the Costs of Compliance is smaller.

Manufacturer's Service Information

    We have reviewed and approved the technical contents of IAE SB V-
2500-ENG-72-0452, Revision 3, dated March 4, 2005, that describes 
procedures for MCD inspections for engines in the range V10600 to 
V11365 with No. 3 bearing, P/N 2A1165, installed. We have also reviewed 
and approved the technical contents of IAE SB V-2500-ENG-72-0459, 
Revision 2, dated March 4, 2005, that describes procedures for in shop 
action for engines in the range V10600 to V11365 with No. 3 bearing, P/
N 2A1165, installed.

FAA's Determination of an Unsafe Condition and Proposed Actions

    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:
     Initial inspection of the master MCD or the No. 1, 2, 3 
bearing chamber MCD within 125 hours time-in-service (TIS) after the 
effective date of the proposed AD; and
     Repetitive inspections of the master MCD or the No. 1, 2, 
3 bearing chamber MCD within 125 hours time-since-last inspection; and
     Replacement of the No. 3 bearing, P/N 2A1165, at the next 
shop visit for any reason; and
     Replacement of HPC stubshafts that have a low-energy 
plasma coating with HPC stubshafts that have a high-energy plasma 
coating.

Costs of Compliance

    We estimate that this proposed AD would affect 123 engines 
installed on airplanes of U.S. registry. We also estimate it would take 
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 $33,788 per engine. Based on these figures, we estimate the total 
cost of the proposed AD to U.S. operators to be $5,355,174.

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 Analysis

    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.

[[Page 2493]]

    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 at the 
address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    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. Section 39.13 is amended by removing Amendment 39-13183 (68 FR 
33621, June 5, 2003) and by adding the following new airworthiness 
directive:

International Aero Engines AG (IAE): Docket No. 2003-NE-21-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by March 20, 
2006.

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 with engine serial numbers V10600 through 
V11365 and bearings P/N 2A1165 installed. These engines are 
installed on, but not limited to, Airbus Industrie A319, A320, and 
A321 series airplanes.

Unsafe Condition

    (d) This AD results from reports of No. 3 bearing failures that 
caused 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 an IFSD and smoke in the cockpit and 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 listed in Appendix 1, Tables 1 and 2 of IAE 
service bulletin (SB) V-2500-ENG-72-0452, Revision 3, dated March 4, 
2005, and that have a No. 3 bearing, part number (P/N) 2A1165, 
installed at new production build, do the following:
    (1) Within 125 hours time-in-service (TIS) after the effective 
date of this AD, inspect the master MCD or the No. 1, 2, 3 bearing 
chamber MCD.
    (2) Thereafter, within 125 hours time-since-last inspection, 
inspect the master MCD or 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 listed in Appendix 1, Tables 1 and 2 of IAE SB 
V-2500-ENG-72-0459, Revision 2, dated March 4, 2005, that have a 
serial number (SN) from V10600 through V11365 inclusive, and that 
have a No. 3 bearing, part number (P/N) 2A1165, installed at new 
production, 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 listed in Appendix 1, Tables 1 and 2 of IAE SB 
V-2500-ENG-72-0459, Revision 2, dated March 4, 2005, that have a SN 
from V10600 through V11365 inclusive, at the next shop visit for any 
reason, replace the HPC stubshaft that has a low-energy plasma 
coating with an HPC stubshaft that has a high-energy plasma coating.

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 (AMOCs)

    (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) For lists identifying engines within the engine SN range of 
V10600 to V11365 inclusive, known to have had P/N 2A1165 installed, 
you must use Appendix 1, Tables 1 and 2 of IAE SB V-2500-ENG-72-
0452, Revision 3, dated March 4, 2005, and IAE SB V-2500-ENG-72-
0459, Revision 2, dated March 4, 2005.

Related Information

    (m) The following service bulletins contain additional 
information and procedures:
    (1) 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.
    (2) Additional information on inspection procedures is included 
in IAE SB V-2500-ENG-72-0452, Revision 3, dated March 4, 2005.
    (3) You can find information on replacing the No. 3 bearing, and 
replacing or recoating the HPC stubshaft in IAE SB V-2500-ENG-72-
0459, Revision 2, dated March 4, 2005.

    Issued in Burlington, Massachusetts, on January 9, 2006.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E6-379 Filed 1-13-06; 8:45 am]
BILLING CODE 4910-13-P