[Federal Register Volume 89, Number 24 (Monday, February 5, 2024)]
[Proposed Rules]
[Pages 7636-7639]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2024-02205]


 ========================================================================
 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. 89, No. 24 / Monday, February 5, 2024 / 
Proposed Rules  

[[Page 7636]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2024-0041; Project Identifier AD-2024-00032-E]
RIN 2120-AA64


Airworthiness Directives; International Aero Engines, AG Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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

SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for certain International Aero Engines, AG (IAE AG) Model V2500 
engines. This proposed AD was prompted by an analysis of an event 
involving an International Aero Engines, LLC (IAE LLC) Model PW1127GA-
JM engine, which experienced a high-pressure compressor (HPC) 7th-stage 
integrally bladed rotor (IBR-7) separation that resulted in an aborted 
takeoff. This proposed AD would require performing an angled ultrasonic 
inspection (AUSI) of certain high-pressure turbine (HPT) 1st-stage hubs 
and HPT 2nd-stage hubs for cracks and replacing if necessary. This 
proposed AD would also require accelerated replacement of certain HPT 
1st-stage hubs and HPT 2nd-stage hubs. The FAA is proposing this AD to 
address the unsafe condition on these products.

DATES: The FAA must receive comments on this proposed AD by March 6, 
2024.

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 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.
    AD Docket: You may examine the AD docket at regulations.gov under 
Docket No. FAA-2024-0041; or in person at Docket Operations between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD 
docket contains this NPRM, any comments received, and other 
information. The street address for Docket Operations is listed above.
    Material Incorporated by Reference:
     For Pratt & Whitney (PW) and IAE AG service information 
identified in this NPRM, contact International Aero Engines, AG, 400 
Main Street, East Hartford, CT 06118; phone: (860) 565-0140; email: 
[email protected]; website: connect.prattwhitney.com.
     You may view this service information at the FAA, 
Airworthiness Products Section, Operational Safety Branch, 1200 
District Avenue, Burlington, MA 01803. For information on the 
availability of this material at the FAA, call (817) 222-5110.

FOR FURTHER INFORMATION CONTACT: Carol Nguyen, Aviation Safety 
Engineer, FAA, 2200 South 216th Street, Des Moines, WA 98198; phone: 
(781) 238-7655; email: [email protected].

SUPPLEMENTARY INFORMATION:

Comments Invited

    The FAA invites you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under ADDRESSES. Include ``Docket No. FAA-2024-0041; Project Identifier 
AD-2024-00032-E'' at the beginning of your comments. The most helpful 
comments reference a specific portion of the proposal, explain the 
reason for any recommended change, and include supporting data. The FAA 
will consider all comments received by the closing date and may amend 
this proposal because of those comments.
    The FAA has been informed that PW has done some outreach with 
affected operators regarding the proposed corrective actions for this 
unsafe condition. As a result, affected operators are already aware of 
the proposed corrective actions and, in some cases, have already begun 
planning for replacement of the affected parts. Therefore, the FAA has 
determined that a 30-day comment period is appropriate given the 
particular circumstances related to the proposed correction of this 
unsafe condition.
    Except for Confidential Business Information (CBI) as described in 
the following paragraph, and other information as described in 14 CFR 
11.35, the FAA will post all comments received, without change, to 
regulations.gov, including any personal information you provide. The 
agency will also post a report summarizing each substantive verbal 
contact received about this NPRM.

Confidential Business Information

    CBI is commercial or financial information that is both customarily 
and actually treated as private by its owner. Under the Freedom of 
Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public 
disclosure. If your comments responsive to this NPRM contain commercial 
or financial information that is customarily treated as private, that 
you actually treat as private, and that is relevant or responsive to 
this NPRM, it is important that you clearly designate the submitted 
comments as CBI. Please mark each page of your submission containing 
CBI as ``PROPIN.'' The FAA will treat such marked submissions as 
confidential under the FOIA, and they will not be placed in the public 
docket of this NPRM. Submissions containing CBI should be sent to Carol 
Nguyen, Aviation Safety Engineer, FAA, 2200 South 216th Street, Des 
Moines, WA 98198. Any commentary that the FAA receives which is not 
specifically designated as CBI will be placed in the public docket for 
this rulemaking.

Background

    On December 24, 2022, an Airbus Model A320neo airplane, powered by 
IAE LLC Model PW1127GA-JM engines, experienced a failure of the HPC 
IBR-7 that resulted in an engine shutdown and aborted take-off. 
Following this event, the manufacturer conducted a records review of 
production and field-returned parts and re-evaluated their engineering 
analysis methodology. The new analysis found that the failure of the 
HPC IBR-7 was caused by a nickel powdered metal anomaly, similar in 
nature to an anomaly previously observed on March 18, 2020, when an

[[Page 7637]]

Airbus Model A321-231 airplane, powered by IAE AG Model V2533-A5 
engines, experienced an uncontained HPT 1st-stage hub failure that 
resulted in high-energy debris penetrating the engine cowling. The 
analysis also concluded that there is an increased risk of failure for 
a subpopulation of HPT 1st-stage hubs and HPT 2nd-stage hubs that were 
manufactured from the same production campaign (a batch of nickel 
powdered metal) as the HPT 1st-stage hub that failed on March 18, 2020; 
these parts have a higher likelihood of containing the nickel powdered 
metal anomaly and are susceptible to failure much earlier than 
previously determined. As a result, the FAA is proposing an accelerated 
AUSI for certain HPT 1st-stage hubs and HPT 2nd-stage hubs and, 
depending on the results of the inspections, replacing the HPT 1st-
stage hubs or HPT 2nd-stage hubs. This proposed AD would also require 
accelerated replacement of certain HPT 1st-stage hubs and HPT 2nd-stage 
hubs. Certain IAE AG Model V2522-A5, V2524-A5, V2525-D5, V2527-A5, 
V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, V2531-E5, and V2533-A5 
engines are among the products affected by this condition, which, if 
not addressed, could result in hub failure, release of high-energy 
debris, damage to the engine, damage to the airplane, and possible loss 
of the airplane.

FAA's Determination

    The FAA is issuing this NPRM after determining that the unsafe 
condition described previously is likely to exist or develop on other 
products of the same type design.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed IAE AG Non-Modification Service Bulletin (NMSB) 
V2500-ENG-72-0720, dated November 20, 2023; and PW Special Instruction 
NO. 189F-23, dated November 20, 2023 which only applies to the IAE AG 
V2531-E5 Model engine. This service information specifies procedures 
for performing an AUSI for cracks on affected HPT 1st-stage hubs and 
HPT 2nd-stage hubs. This service information also specifies the list of 
affected HPT 1st-stage hubs and HPT 2nd-stage hubs, identified by part 
number and serial number, installed on certain IAE AG engines.
    This service information is reasonably available because the 
interested parties have access to it through their normal course of 
business or by the means identified in ADDRESSES.

Proposed AD Requirements in This NPRM

    This proposed AD would require performing an AUSI of certain HPT 
1st-stage hubs and HPT 2nd-stage hubs and, depending on the results of 
the inspections, replacing the HPT 1st-stage hubs or HPT 2nd-stage 
hubs. This proposed AD would also require accelerated replacement of 
certain HPT 1st-stage hubs and HPT 2nd-stage hubs.

Interim Action

    The FAA considers this proposed AD to be an interim action. The 
unsafe condition is still under investigation by the manufacturer and, 
depending on the results of that investigation, the FAA may consider 
further rulemaking action.

Costs of Compliance

    The FAA estimates that this AD, if adopted as proposed, would 
affect 116 engines installed on airplanes of U.S. registry. The FAA 
estimates that 40 engines would need an AUSI of the HPT 1st-stage hub; 
40 engines would need an AUSI of the HPT 2nd-stage hub; 67 engines 
would need replacement of the HPT 1st-stage hub; and 49 engines would 
need replacement of the HPT 2nd-stage hub.
    The FAA estimates the following costs to comply with this proposed 
AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
AUSI of HPT 1st-stage hub.............  5 work-hours x $85 per                $0            $425         $17,000
                                         hour = $425.
AUSI of HPT 2nd-stage hub.............  5 work-hours x $85 per                 0             425          17,000
                                         hour = $425.
Replace HPT 1st-stage hub.............  100 work-hours x $85 per         460,000         468,500      31,389,500
                                         hour = $8,500.
Replace HPT 2nd-stage hub.............  100 work-hours x $85 per         360,000         368,500      18,056,500
                                         hour = $8,500.
----------------------------------------------------------------------------------------------------------------

    The FAA has included all known costs in its cost estimate. 
According to the manufacturer, however, some of the costs of this AD 
may be covered under warranty, thereby reducing the cost impact on 
affected operators.

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.
    The FAA is 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

    The FAA 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) Would not affect intrastate aviation in Alaska, 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.

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:

[[Page 7638]]

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. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

International Aero Engines, AG: Docket No. FAA-2024-0041; Project 
Identifier AD-2024-00032-E.

(a) Comments Due Date

    The FAA must receive comments on this airworthiness directive 
(AD) by March 6, 2024.

(b) Affected ADs

    This AD is related to AD 2022-02-09, Amendment 39-21906 (87 FR 
7029, February 8, 2022) (AD 2022-02-09).

(c) Applicability

    This AD applies to International Aero Engines, AG (IAE AG) Model 
V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-
D5, V2530-A5, V2531-E5, and V2533-A5 engines.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7230, Turbine 
Engine.

(e) Unsafe Condition

    This AD was prompted by an analysis of an event involving an 
International Aero Engines, LLC Model PW1127GA-JM engine, which 
experienced failure of a high-pressure compressor 7th-stage 
integrally bladed rotor that resulted in an engine shutdown and 
aborted takeoff. The FAA is issuing this AD to prevent failure of 
the high-pressure turbine (HPT) 1st-stage hub and HPT 2nd-stage hub. 
The unsafe condition, if not addressed, could result in uncontained 
hub failure, release of high-energy debris, damage to the engine, 
damage to the airplane, and loss of the airplane

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Required Actions

    (1) For engines with an installed part, part number (P/N), and 
serial number (S/N) listed in Table 1 to paragraph (g)(1) of this 
AD, with no angled ultrasonic inspection (AUSI) performed or the 
AUSI inspected part was installed on or after November 1, 2023, at 
the next engine shop visit after the effective date of this AD 
before exceeding the applicable cycle limit specified in Table 1 to 
paragraph (g)(1) of this AD, perform an AUSI of the affected parts 
for cracks in accordance with the applicable service information 
listed in Table 1 to paragraph (g)(1) of this AD.

                               Table 1 to Paragraph (g)(1)--AUSI Compliance Times
----------------------------------------------------------------------------------------------------------------
                                                      Previously operated    Cycle limit from      Applicable
              Part                  Table S/N is      in high-thrust model    the effective         service
                                      listed in              engine          date of this AD      information
----------------------------------------------------------------------------------------------------------------
HPT 1st-stage hub P/N 2A5001...  Table 1 of IAE AG   Yes..................  100 flight cycles  Accomplishment
                                  Non-Modification                           (FCs).             Instructions,
                                  Service Bulletin                                              paragraph 5., of
                                  V2500-ENG-72-0720                                             IAE AG NMSB
                                  , dated November                                              V2500-ENG-72-072
                                  20, 2023 (IAE AG                                              0.
                                  NMSB V2500-ENG-72-
                                  0720).
                                 Table 1 of Pratt &                                            Accomplishment
                                  Whitney (PW)                                                  Instructions,
                                  Special                                                       paragraph 5., of
                                  Instruction NO.                                               PW SI 189F-23.
                                  189F-23, dated
                                  November 20, 2023
                                  (PW SI 189F-23).
                                 Table 1 of IAE AG   No...................  700 FCs..........  Accomplishment
                                  NMSB V2500-ENG-72-                                            Instructions,
                                  0720.                                                         paragraph 5., of
                                                                                                IAE AG NMSB
                                                                                                V2500-ENG-72-072
                                                                                                0.
HPT 2nd-stage hub P/N 2A4802...  Table 2 of IAE AG   Yes..................  800 FCs..........  Accomplishment
                                  NMSB V2500-ENG-72-                                            Instructions,
                                  0720.                                                         paragraph 6., of
                                                                                                IAE AG NMSB
                                                                                                V2500-ENG-72-072
                                                                                                0.
                                 Table 2 PW SI 189F-                                           Accomplishment
                                  23.                                                           Instructions,
                                                                                                paragraph 6., of
                                                                                                PW SI 189F-23.
                                 Table 2 of IAE AG   No...................  1100 FCs.........  Accomplishment
                                  NMSB V2500-ENG-72-                                            Instructions,
                                  0720.                                                         paragraph 6., of
                                                                                                IAE AG NMSB
                                                                                                V2500-ENG-72-072
                                                                                                0.
----------------------------------------------------------------------------------------------------------------

    (2) For parts inspected in accordance with paragraph (g)(1) of 
this AD, within 4,000 FCs from accomplishment of the AUSI required 
by paragraph (g)(1) of this AD or at the next HPT module removal 
after the AUSI required by paragraph (g)(1) of this AD, whichever 
occurs first, remove the part from service and replace with a part 
eligible for installation.
    (3) If any crack is found during the inspections required by 
paragraphs (g)(1) of this AD, before further flight, remove the 
affected part from service and replace with a part eligible for 
installation.
    (4) For engines with an AUSI inspected part installed prior to 
November 1, 2023, having a P/N and S/N listed in Table 2 to 
paragraph (g)(4) of this AD, at the next HPT module removal after 
the effective date of this AD, but before exceeding the applicable 
cycle limit specified in Table 2 to paragraph (g)(4) of this AD, 
remove the affected part from service and replace with a part 
eligible for installation.

                         Table 2 to Paragraph (g)(4)--Part Replacement Compliance Times
----------------------------------------------------------------------------------------------------------------
                                                                 Previously operated
               Part                   Table S/N is listed in     in high-thrust model     Cycle limit from the
                                                                        engine         effective date of this AD
----------------------------------------------------------------------------------------------------------------
HPT 1st-stage hub P/N 2A5001......  Table 1 of IAE AG NMSB      Yes..................  1,800 FCs.
                                     V2500-ENG-72-0720.
                                    Table 1 of PW SI 189F-23..
                                    Table 1 of IAE AG NMSB      No...................  2,800 FCs.
                                     V2500-ENG-72-0720.
HPT 2nd-stage hub P/N 2A4802......  Table 2 of IAE AG NMSB      Yes..................  3,400 FCs.
                                     V2500-ENG-72-0720.
                                    Table 2 of PW SI 189F-23..

[[Page 7639]]

 
                                    Table 2 of IAE AG NMSB      No...................  3,800 FCs.
                                     V2500-ENG-72-0720.
----------------------------------------------------------------------------------------------------------------

    (5) For engines with an installed part that has a P/N and S/N 
listed in Table 3 to paragraph (g)(5) of this AD, at the next HPT 
module removal after the effective date of this AD, but before 
exceeding the applicable cycle limit specified in Table 3 to 
paragraph (g)(5) of this AD, remove the affected part from service 
and replace with a part eligible for installation.

                         Table 3 to Paragraph (g)(5)--Part Replacement Compliance Times
----------------------------------------------------------------------------------------------------------------
                                                                 Previously operated
               Part                   Table S/N is listed in     in high-thrust model     Cycle limit from the
                                                                        engine         effective date of this AD
----------------------------------------------------------------------------------------------------------------
HPT 1st-stage hub P/N 2A5001......  Table 3 of IAE AG NMSB      Yes..................  1,800 FCs.
                                     V2500-ENG-72-0720.         No...................  2,800 FCs.
                                    Table 3 of IAE AG NMSB
                                     V2500-ENG-72-0720.
HPT 2nd-stage hub P/N 2A4802......  Table 4 of IAE AG NMSB      Yes..................  3,400 FCs.
                                     V2500-ENG-72-0720.         No...................  3,800 FCs.
                                    Table 4 of IAE AG NMSB
                                     V2500-ENG-72-0720.
----------------------------------------------------------------------------------------------------------------

(h) Definitions

    (1) For the purposes of this AD, a ``part eligible for 
installation'' is an HPT 1st-stage disk or HPT 2nd-stage disk having 
an S/N that is not listed in IAE AG NMSB V2500-ENG-72-0720 or PW SI 
189F-23.
    (2) For the purposes of this AD, an ``HPT module removal'' is 
when the HPT rotor and stator assembly are removed from the engine.
    (3) For the purposes of this AD, ``Previously operated in high-
thrust model engine'' refers to HPT 1st-stage hubs or HPT 2nd-stage 
hubs that have previously operated in an IAE AG Model V2527E-A5, 
V2527M-A5, V2528-D5, V2530-A5, V2531-E5, or V2533-A5 engine for any 
duration.
    (4) For the purposes 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, H-P, except for 
the following situations, which do not constitute an engine shop 
visit:
    (i) Separation of engine flanges solely for the purposes of 
transportation without subsequent engine maintenance.
    (ii) Engine removal for the purpose of performing field 
maintenance activities at a maintenance facility in lieu of 
performing them on-wing.
    (5) For the purposes of this AD, the date that an AUSI inspected 
part was installed is the date of the authorized release 
certification for the shop visit at which the part was first 
installed after the AUSI was performed.

(i) Terminating Action to AD 2022-02-09

    Compliance with paragraph (g)(1) of this AD satisfies the 
requirements of AD 2022-02-09.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, AIR-520 Continued Operational Safety Branch, 
FAA, has the authority to approve AMOCs for this AD, if requested 
using the procedures found in 14 CFR 39.19. In accordance with 14 
CFR 39.19, send your request to your principal inspector or local 
Flight Standards District Office, as appropriate. If sending 
information directly to the manager of the AIR-520 Continued 
Operational Safety Branch, send it to the attention of the person 
identified in paragraph (k) of this AD.
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.

(k) Additional Information

    For more information about this AD, contact Carol Nguyen, 
Aviation Safety Engineer, FAA, 2200 South 216th Street, Des Moines, 
WA 98198; phone: (781) 238-7655; email: [email protected].

(l) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) International Aero Engines AG (IAE AG) Non-Modification 
Service Bulletin V2500-ENG-72-0720, dated November 20, 2023.
    (ii) Pratt & Whitney (PW) Special Instruction NO. 189F-23, dated 
November 20, 2023.
    (3) For PW and IAE AG service information identified in this AD, 
contact International Aero Engines, AG, 400 Main Street, East 
Hartford, CT 06118; phone: (860) 565-0140; email: [email protected]; 
website: connect.prattwhitney.com.
    (4) You may view this service information at the FAA, 
Airworthiness Products Section, Operational Safety Branch, 1200 
District Avenue, Burlington, MA 01803. For information on the 
availability of this material at the FAA, call (817) 222-5110.
    (5) You may view this material at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations or email [email protected].

    Issued on January 24, 2024.
Victor Wicklund,
Deputy Director, Compliance & Airworthiness Division, Aircraft 
Certification Service.
[FR Doc. 2024-02205 Filed 1-31-24; 4:15 pm]
BILLING CODE 4910-13-P