[Federal Register Volume 79, Number 191 (Thursday, October 2, 2014)]
[Proposed Rules]
[Pages 59461-59463]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2014-23561]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2014-0462; Directorate Identifier 2014-NE-06-AD]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce Corporation Turboprop and 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to adopt a new airworthiness directive (AD) for 
certain Rolls-Royce Corporation (RRC) AE 2100 series turboprop engines 
and AE 3007A and 3007C series turbofan engines. This proposed AD was 
prompted by reports of pitting in the wheel bores and subsequent RRC 
analysis that concluded that lower life limits are needed for the 
affected turbine wheels. This proposed AD would reduce the approved 
life limits of the affected turbine wheels. This proposed AD would also 
require an eddy current inspection (ECI) of certain RRC engines with 
affected turbine wheels. We are proposing this AD to prevent 
uncontained failure of the turbine wheels, damage to the engine, and 
damage to the airplane.

DATES: We must receive comments on this proposed AD by December 1, 
2014.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Rolls-Royce Corporation, 450 South Meridian Street, Mail Code NB-01-06, 
Indianapolis, IN 46225, phone: 317-230-1667; email: royce.com">CMSEindyOSD@rolls-royce.com; Internet: www.rolls-royce.com. You may view this service 
information at the FAA, Engine & Propeller Directorate, 12 New England 
Executive Park, Burlington, MA. For information on the availability of 
this material at the FAA, call 781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2014-
0462; or in person at the Docket Management Facility between 9 a.m. and 
5 p.m., Monday through Friday, except Federal holidays. The AD docket 
contains this proposed AD, the regulatory evaluation, any comments 
received, and other information. The street address for the Docket 
Office (phone: 800-647-5527) is in the ADDRESSES section. Comments will 
be available in the AD docket shortly after receipt.

FOR FURTHER INFORMATION CONTACT: Kyri Zaroyiannis, Aerospace Engineer, 
Chicago Aircraft Certification Office, Small Airplane Directorate, FAA, 
2300 E. Devon Ave., Des Plaines, IL 60018; phone: 847-294-7836; fax: 
847-294-7834; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2014-0462; 
Directorate Identifier 2014-NE-06-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy

[[Page 59462]]

aspects of this proposed AD. We will consider all comments received by 
the closing date and may amend this proposed AD because of those 
comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact we 
receive about this proposed AD.

Discussion

    Inspections during the manufacturing process revealed higher than 
normal pitting in the bore of certain turbine wheels due to a 
permanganate cleaning process. Analysis and subsequent testing by RRC 
of these affected turbine wheels indicated that these wheels, because 
of the potential for pitting in the wheel bores, could not be operated 
safely up to their published life limits. For RRC AE 2100 series 
turboprop engines, the affected turbine wheels are identified as 1st 
stage gas generator turbine wheels and as 4th stage turbine wheels. For 
the RRC AE 3007A and 3007C series turbofan engines, the affected 
turbine wheels are identified as high-pressure turbine (HPT) stage 1 
and stage 2 wheels. Operation of the affected wheels above the new 
lower limits represents an unsafe condition.
    We are also proposing an ECI for certain RRC AE 3007A engines with 
affected turbine wheels because our risk analysis shows that these 
engines are operated in a more stringent environment and therefore 
require periodic inspections to ensure these engines are operated 
safely.
    This condition, if not corrected, could result in uncontained 
failure of the turbine wheels, damage to the engine, and damage to the 
airplane.

Relevant Service Information

    We reviewed RRC Alert Service Bulletin (ASB) No. AE 2100D2-A-72-
085, dated July 25, 2013; RRC ASB No. AE 2100D3-A-72-277, dated July 
25, 2013; RRC ASB No. AE 2100P-A-72-019, dated July 25, 2013; RRC ASB 
No. AE 3007A-A-72-407, Revision 1, dated August 29, 2014; RRC ASB No. 
AE 3007A-A-72-408, Revision 1, dated August 29, 2014; and RRC ASB No. 
AE 3007C-A-72-316, dated December 6, 2013. RRC ASB No. AE 3007A-A-72-
408 provides instructions on performing an ECI of affected HPT stage 2 
wheels. The other RRC ASBs list the lower approved life limits of the 
affected turbine wheels.

FAA's Determination

    We are proposing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design.

Proposed AD Requirements

    This proposed AD would require an ECI of certain RRC engines with 
affected turbine wheels, and reduce the life limits of the affected 
turbine wheels.

Costs of Compliance

    We estimate that this proposed AD would affect 664 engines 
installed on airplanes of U.S. registry. We also estimate that it would 
take about 1 hour to perform an ECI in the bore of the turbine wheel 
for affected engines. The average labor rate is $85 per work-hour. We 
estimate the pro-rated replacement cost would be $30,688 for a 1st 
stage gas generator turbine wheel; $63,693 for an HPT stage 1 wheel; 
$13,941 for an HPT stage 2 wheel; and $13,186 for a 4th stage turbine 
wheel. We also estimate that these parts would be replaced during an 
engine shop visit at no additional labor cost. Based on these figures, 
we estimate the total cost of the AD to U.S. operators to be 
$11,317,969.

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 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 this 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),
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction, and
    (4) 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.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
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]

0
2. Amend Sec.  39.13 by adding the following new airworthiness 
directive (AD):

Rolls Royce Corporation (Formerly Allison Engine Company): Docket 
No. FAA-2014-0462; Directorate Identifier 2014-NE-06-AD.

(a) Comments Due Date

    We must receive comments by December 1, 2014.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to all Rolls-Royce Corporation (RRC) AE 2100D2, 
2100D2A, 2100D3, and 2100P turboprop engines and AE 3007A1, A1/1, 
A1/3, A1E, A1P, A2, A3, C, C1, and C2 turbofan engines:
    (1) With an installed 1st stage gas generator turbine wheel, 
part number (P/N) 23079946, 23088906, or 23089692, all serial 
numbers (S/Ns) listed in Table 2 and Table 3 of RRC Alert Service 
Bulletin (ASB) No. AE 2100D2-A-72-085, dated July 25, 2013; and in 
Table 2 and Table 3 of RRC ASB No. AE 2100D3-A-72-277, dated July 
25, 2013.
    (2) With an installed high-pressure turbine (HPT) stage 1 or HPT 
stage 2 wheel, P/N 23079946, 23088906, 23088784, 23084520, 23084781, 
23088817, or 23088818, all S/Ns listed in Table 1 through Table 7 of 
RRC ASB

[[Page 59463]]

No. AE 3007A-A-72-407, Revision 1, dated August 29, 2014, except 
those S/Ns excluded by Table 1, Table 2, Table 4, and Table 5 of RRC 
ASB No. AE 3007A-A-72-407, Revision 1, dated August 29, 2014.
    (3) With an installed HPT stage 2 wheel, P/N 23084520 or 
23088818, all S/Ns listed in Table 1 and Table 2 of RRC ASB No. AE 
3007C-A-72-316, dated December 6, 2013, except those S/Ns excluded 
by Table 1 of RRC ASB No. AE 3007C-A-72-316, dated December 6, 2013.
    (4) With an installed 4th stage turbine wheel, P/N 23083536, all 
S/Ns listed in Table 2 of RRC ASB No. AE 2100P-A-72-019, dated July 
25, 2013.

(d) Unsafe Condition

    This AD was prompted by reports of pitting in the wheel bores 
and subsequent RRC analysis that concluded that lower life limits 
are needed for the affected turbine wheels. We are issuing this AD 
to prevent uncontained failure of the turbine wheels, damage to the 
engine, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) For all RRC AE 3007A1, A1/1, A1/3, A1E, A1P, and A3 series 
engines with an HPT stage 2 wheel P/N and S/N identified in RRC ASB 
No. AE 3007A-A-72-408, Revision 1, dated August 29, 2014, at each 
shop visit after the effective date of this AD, eddy current inspect 
the bore of the affected HPT stage 2 wheels. Use RRC ASB AE 3007A-A-
72-408, Revision 1, August 29, 2014, to do the inspection. Do not 
return to service any wheel that fails the inspection required by 
this AD.
    (2) Thirty days after the effective date of this AD, do not 
return to service any engine that has a turbine wheel with a P/N and 
an S/N listed in any of the following RR ASBs whose wheel life 
exceeds the new life limits identified in the RR ASBs:
    RRC ASB No. AE 2100D2-A-72-085, dated July 25, 2013;
    RRC ASB No. AE 2100D3-A-72-277, dated July 25, 2013;
    RRC ASB No. AE 2100P-A-72-019, dated July 25, 2013;
    RRC ASB No. AE 3007A-A-72-407, Revision 1, dated August 29, 
2014; or
    RRC ASB No. AE 3007C-A-72-316, dated December 6, 2013.

(f) Installation Prohibition

    Thirty days after the effective date of this AD, do not install 
an affected wheel, as identified in paragraph (c) of this AD, into 
any RRC AE 3007C2 engine.

(g) Definition

    For the purpose of this AD, an ``engine shop visit'' is the 
induction of an engine into the shop for maintenance involving the 
separation of pairs of major mating engine flanges, except that the 
separation of engine flanges solely for the purposes of 
transportation without subsequent engine maintenance is not an 
engine shop visit.

(h) Alternative Methods of Compliance (AMOCs)

    The Manager, Chicago Aircraft Certification Office, FAA, may 
approve AMOCs for this AD. Use the procedures found in 14 CFR 39.19 
to make your request.

(i) Related Information

    (1) For more information about this AD, contact Kyri 
Zaroyiannis, Aerospace Engineer, Chicago Aircraft Certification 
Office, Small Airplane Directorate, FAA, 2300 E. Devon Ave., Des 
Plaines, IL 60018; phone: 847-294-7836; fax: 847-294-7834; email: 
[email protected].
    (2) RRC ASB No. AE 2100D2-A-72-085, dated July 25, 2013; RRC ASB 
No. AE 2100D3-A-72-277, dated July 25, 2013; RRC ASB No. AE 2100P-A-
72-019, dated July 25, 2013; RRC ASB No. AE 3007A-A-72-407, Revision 
1, dated August 29, 2014; RRC ASB No. AE 3007A-A-72-408, Revision 1, 
dated August 29, 2014; and RRC ASB No. AE 3007C-A-72-316, dated 
December 6, 2013, which are not incorporated by reference in this 
AD, can be obtained from RRC using the contact information in 
paragraph (i)(3) of this AD.
    (3) For service information identified in this AD, contact 
Rolls-Royce Corporation, 450 South Meridian Street, Mail Code NB-01-
06, Indianapolis, IN 46225, phone: 317-230-1667; email: 
royce.com">CMSEindyOSD@rolls-royce.com; Internet: www.rolls-royce.com.
    (4) You may view this service information at the FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, 
MA. For information on the availability of this material at the FAA, 
call 781-238-7125.

    Issued in Burlington, Massachusetts, on September 25, 2014.
Colleen M. D'Alessandro,
Assistant Directorate Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2014-23561 Filed 10-1-14; 8:45 am]
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